Method and apparatus for manufacturing electrode assembly for rectangular battery

ABSTRACT

In a method of manufacturing an electrode assembly for a rectangular battery, in which positive electrodes and negative electrodes are alternately laminated so that a separator exists between the respective positive and negative electrodes, the manufacturing method includes the steps of: arranging a plurality of guide members in zigzag form in a perpendicular direction; inserting a continuous member of the separator between one and another one rows of the guide members; folding, into zigzag form, the continuous member by intersecting the rows of the guide members in a horizontal direction; inserting alternately the positive electrodes and the negative electrodes in respective valley grooves of the zigzag-folded continuous member; withdrawing the guide members from the respective valley grooves of the continuous member; and pressing, thereafter, the continuous member in the zigzag direction so as to make flat the continuous member.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to method of and apparatus formanufacturing an electrode assembly adapted for a battery having arectangular structure, called “rectangular battery” hereinlater.

2. Related Art

An electrode assembly in a battery such as lithium ion secondary batteryor cell is formed by alternately laminating positive electrodes andnegative electrodes with a separator being disposed between a positiveelectrode and a negative electrode. Such electrode assembly may bemanufactured by the following typical methods.

(1) Laminate Method: a separator, a positive electrode and a negativeelectrode, which are all formed in shape of sheet, are laminated suchthat the separator is disposed between the positive electrode and thenegative electrode (for example, refer to the following Patent Document5)

(2) Wind-up Method: a separator, a positive electrode and a negativeelectrode, which are all formed continuously, are wound up in form ofeddy-shape such that the separator is disposed between the positiveelectrode and the negative electrode (for example, refer to thefollowing Patent Documents 5, 6 and 7).

(3) Zigzag-Stack Method: a continuous member of a separator, or alaminated member of a continuous member of the separator and acontinuous member of a negative electrode is folded in zigzag shape, andthen, both sheet-shaped positive electrode and negative electrode oronly a positive electrode is inserted into a valley groove of thelaminated member, which is then crushed in flat shape (for example,refer to the following Patent Documents 1, 2, 3 and 4).

[Patent Document 1] Japanese Patent Laid-open Publication No. 2004-22449

[Patent Document 2] Japanese Patent Laid-open Publication No. HEI1-122572

[Patent Document 3] Japanese Patent Laid-open Publication No. HEI1-100871

[Patent Document 4] Japanese Patent Laid-open Publication No.2006-190531

[Patent Document 5] Japanese Patent Laid-open Publication No.2002-329530

[Patent Document 6] Japanese Patent Laid-open Publication No.2000-223109

[Patent Document 7] Japanese Patent Laid-open Publication No. HEI 7-6783

In the laminate-method of the above (1), however, it is difficult toensure the positional performance of the positive and negativeelectrodes and the separator, and in an adverse case in which theirpositions are shifted, the positive and negative electrodes may beshort-circuited. When precise positional arrangement is made to preventsuch short-circuiting, it may result in delay of takt time manufacturingspeed per one electrode assembly), which may result in reduction ofproductivity of the electrode assembly, i.e., batteries.

In the wind-up method of the above (2), if the electrode assembly iswound up in too many turns, a space between the electrode assembly and acorner portion of a battery case may provide a dead space and electriccapacity may be reduced, thus providing a problem.

The zigzag-stack method of the above (3) has merits such that incomparison with the above laminate-method, the positional performancebetween the positive and negative electrodes and the separator can beimproved and the takt time can be reduced, and in addition, incomparison with the above wind-up method, the dead space can be reducedand the electric capacity can be increased.

In the conventional zigzag-stack method, for example, in the structureof the above Patent Document 1, however, a continuous separator ispinched by a pair of rollers and the paired rollers are reciprocated inthe horizontal direction to thereby fold the separator in zigzag formand the positive and negative electrodes are alternately overlapped onthe separator each time of the reciprocal motion of the paired rollers.This operation makes delay the takt time, which results in reduction ofproductivity, thus providing a problem.

Furthermore, in this zigzag-stack method, since it is intended to foldthe separator in zigzag form on curved surfaces of the rollers, it isdifficult to accurately fold the separator in the zigzag form and,hence, the separator, i.e., the electrode assembly, likely becomewarped, which may result in deterioration of performance of the battery.In addition, when the separator is folded in the zigzag form, theseparator is moved in a meandering manner and, hence, is not accuratelyfolded.

In the technology disclosed in the above Patent Document 2, it isintended to form the electrode assembly by clamping the continuousseparator in the zigzag form between the hard positive electrode andnegative electrode held with a constant interval, so that it may pose aproblem such that the separator is likely broken by a large tension(load) applied to the separator, and in a case that the electrode isthin and soft, its manufacture is made difficult, thus also providing aproblem.

In the structure disclosed in the above Patent Document 3, thezigzag-shaped separator is manufactured by placing the continuousseparator on a saw-teeth shaped female mold half and sequentiallyinserting a male mold half having a shape corresponding to one grooveinto respective grooves. Next, the positive electrodes and the negativeelectrodes are respectively alternately inserted into the respectivevalley grooves of the separator, and finally, the separator is pressedtogether with the positive and negative electrodes to make the separatorto provide a flat shape. In such method, the takt time is elongated andit is difficult to enhance the productivity.

In the structure disclosed in the above Patent Document 4, it isintended to manufacture the electrode assembly by pressing, in form ofzigzag shape with a saw-teeth shaped male and female molds, a member inwhich the continuous separator is sandwiched between the continuouspositive and negative electrodes and then pressing the thus formedzigzag-shaped laminated member. Therefore, in this manufacturing method,the zigzag-folding of the electrode assembly is made fine and theelectric capacity is hence reduced, thus providing a problem. Inaddition, both the positive and negative electrodes are mutuallycontacted at certain positions, so that the positive electrodes and thenegative electrodes may include portions not contributing to powergeneration, thus also providing a problem

SUMMARY OF THE INVENTION

The present invention was conceived in consideration of thecircumstances encountered in the prior art mentioned above, and hence,an object of the present invention is to provide method of and apparatusfor accurately manufacturing an electrode assembly for a rectangularbattery or cell with high performance and with short takt time.

The above and other objects of the present invention will be achieved byproviding, in one aspect, a method of manufacturing an electrodeassembly for a rectangular battery, in which positive electrodes andnegative electrodes are alternately laminated so that a separator existsbetween the respective positive and negative electrodes, themanufacturing method comprising the steps of:

arranging a plurality of guide members in zigzag form in a perpendiculardirection;

inserting a continuous member of the separator between one and anotherone rows of the guide members;

folding, into zigzag form, the continuous member by intersecting therows of the guide members in a horizontal direction;

inserting alternately the positive electrodes and the negativeelectrodes in respective valley grooves of the zigzag-folded continuousmember;

withdrawing the guide members from the respective valley grooves of thecontinuous member; and

pressing, thereafter, the continuous member in the zigzag direction soas to make flat the continuous member.

According to this aspect, it is possible to form necessary number of thevalley grooves for one electrode assembly simultaneously to thecontinuous member of the separator, and accordingly, the takt time canbe remarkably reduced. In addition, the separator is zigzag-folded byintersecting the rows of the guide members with each other, so that deepvalley grooves can be formed, and the positive electrodes and thenegative electrodes can be made large to thereby form a large electrodeassembly having large electric capacity. Furthermore, even if thepositive and negative electrodes are made of thin and soft material,they can be smoothly inserted into the valley grooves of the separator.

In the above aspect, the positive electrodes and the negative electrodesmay be alternately inserted into the respective valley grooves of thecontinuous member while folding the continuous member by intersectingthe respective rows of the guide members.

According to this embodiment, the zigzag-folding of the continuousmember and the insertion of the positive and negative electrodes can besimultaneously performed, so that the takt time can be further reduced.

In another aspect of the present invention, there is provided a methodof manufacturing an electrode assembly for a rectangular battery, inwhich positive and negative electrodes are alternately laminated so thata separator exists between the respective positive and negativeelectrodes, the manufacturing method comprising the steps of:

arranging a plurality of guide members in zigzag form in a perpendiculardirection;

inserting an laminated member, in which a continuous member of thenegative electrode is sandwiched between two rows of a continuous memberof the separator, between one and another rows of the guide members;

folding, into zigzag form, the laminated member by intersecting the rowsof the guide members in a horizontal direction;

inserting the positive electrodes in respective valley grooves of thezigzag-folded continuous member;

withdrawing the guide members from the respective valley grooves of thelaminated member; and

pressing, thereafter, the laminated member in the zigzag direction so asto make flat the laminated member.

According to the invention of this aspect, the valley grooves necessaryfor one electrode assembly can be simultaneously formed to the laminatedmember, so that the takt time can be remarkably reduced.

In addition, according to this aspect, the electrode assembly of thesame layer numbers as that of the first aspect mentioned above can bemanufactured by the guide members of the number less than that of theabove-mentioned first aspect, or by using the same number of the guidemembers as that of the first aspect, the electrode assembly having thetwice layer number can be manufactured in comparison with the inventionof the first aspect.

Furthermore, since the laminated member is folded into zigzag form byintersecting the rows of the guide members, the valley grooves havingdeep depth can be manufactured, and accordingly, the electrode assemblyhaving large positive electrode and large electric capacity.

In an embodiment according to the above another aspect, the positiveelectrodes may be inserted into the respective valley grooves of thelaminated member while folding the laminated member by intersecting therespective rows of the guide members.

According to this embodiment, the zigzag-folding of the laminated memberand the insertion of the positive electrodes can be simultaneouslyperformed, and accordingly, the takt time can be further reduced. Inaddition, as mentioned above, in comparison with the embodiment of thefirst aspect mentioned above, the electrode assembly having the largenumber of layers can be manufactured, or by using the same number of theguide members, the electrode assembly having the twice layer number canbe manufactured in comparison with the invention of the above embodimentof the first aspect.

In an embodiment of the above one (first) and another aspects, adistance between the rows of the guide members is narrowed afterinsertion of both the positive and negative electrodes or only thepositive electrodes into the valley grooves of the continuous member orlaminated member in the zigzag form.

According to this embodiment, each of the valley grooves can be formedto have a large opening so that the positive and negative electrodes areeasily inserted, and after the insertion, by narrowing the distancebetween the respective rows of the guide members, the zigzag-shapedcontinuous member or laminated member can be easily made flat.

In an embodiment of the above aspects, both the positive and negativeelectrodes or only the positive electrodes inserted into the valleygrooves of the continuous member or laminated member may be pressed inan extending direction of the valley grooves.

According to this embodiment, the positive electrodes and the negativeelectrodes inserted into the respective valley grooves of the continuousmember or laminated member can be accurately positioned in thelongitudinal direction thereof.

In an embodiment of the above aspects, when the guide members arewithdrawn from the respective valley grooves of the continuous member orlaminated member, the continuous member or laminated member may bepressed in the zigzag direction.

According to this embodiment, the zigzag-shaped continuous member orlaminated member is not deformed at the time of withdrawing the guidemembers.

In an embodiment of the above aspects, after the guide members arewithdrawn from the respective valley grooves of the continuous member orlaminated member, the positive and negative electrodes may be furtherpushed into the respective valley grooves before the pressing of thecontinuous member or laminated member into a flat shape.

According to this embodiment, the positive and negative electrodes aremoved to the positions in the valley grooves of the continuous member orlaminated member at which the guide members existed. Accordingly, thearea overlapped by the positive and negative electrodes is increased,resulting in the increasing of the electric capacity and improvement ofthe battery. In addition, the separator can be more effectively used.

In an embodiment of the above aspects, the guide members may beconstructed as guide rods.

According to this embodiment, the guide members can be made compact andlight.

In the above embodiment, the guide rods may be formed as rotatable guiderollers.

According to this embodiment, when the continuous member or laminatedmember is zigzag-folded, tension applied to the continuous member orlaminated member can be loosened to thereby prevent them from beingbroken.

Further, in the above embodiment, the guide rods may be formed assemicircular cylindrical members.

According to this embodiment, the guide rods can be made light-weighted.

In an example of the above one and another aspects, when the rows of theguide members are intersected with each other, air may be ejected fromsurfaces of the guide members toward the continuous member or laminatedmember.

According to this embodiment, when the continuous member or laminatedmember is zigzag-folded, friction between the continuous member orlaminated member and the guide members is reduced and tension applied tothe continuous member or laminated member is loosened to thereby shortenthe time required for the zigzag folding and properly prevent them frombeing broken.

In an embodiment of the above aspects, friction reducing material layersmay be formed to surfaces of the guide members contacting to thecontinuous member or laminated member.

According to this embodiment, when the continuous member or laminatedmember is zigzag-folded, friction between the continuous member orlaminated member and the guide members is reduced and tension applied tothe continuous member or laminated member is loosened to thereby shortenthe time required for the zigzag folding and properly prevent them frombeing broken.

In an embodiment of the above aspects, the guide members may be formedas guide plates.

According to this embodiment, even if the positive and negativeelectrodes are thin and soft, they can be smoothly inserted into thevalley grooves of the separator.

In the above embodiment, the guide plates are formed to inclining platesinclining toward intersecting side front ends thereof.

According to this embodiment, in the case where the guide plates areformed to the inclining plates inclining toward the intersecting sidefront end thereof, the guide plates can be easily inserted into therespective valley grooves of the continuous member or laminated member,the guide plates can be easily withdrawn from the respective valleygrooves, and the time required for the zigzag-folding can be shortened.

In an example of the above embodiment, the rotatable rollers may beattached to the intersecting side front ends of the guide plates.

According to this embodiment, when the continuous member or laminatedmember is zigzag-folded, the tension applied thereto is loosened andthey can be prevented from being broken.

In the above embodiment, when the rows of the guide plates areintersected with each other, air may be ejected from surfaces of therollers toward the continuous member or laminated member.

According to this embodiment, at the time when the continuous member orlaminated member is zigzag-folded, the friction between the continuousmember or laminated member and the guide plates can be reduced, and thetension applied to the continuous member or laminated member can befurther loosened. In addition, the time required for the zigzag-foldingcan be shortened and the breakage of the continuous member or laminatedmember can be suitably prevented.

In the above embodiment, a friction reducing material layer may beformed on a surface of at least one of the roller or guide platecontacting to the continuous member or laminated member.

According to this embodiment, at the time when the continuous member orlaminated member is zigzag-folded, the friction between the continuousmember or laminated member and the guide plates can be reduced, and thetension applied to the continuous member or laminated member can befurther loosened. In addition, the time required for the zigzag-foldingcan be shortened and the breakage of the continuous member or laminatedmember can be suitably prevented.

In an embodiment of the above aspects, the guide members may bewithdrawn from the respective valley grooves of the continuous member orlaminated member, folded lines are formed to bottom portions of therespective valley grooves of the continuous member or laminated member,and thereafter, the continuous member or laminated member is pressed inthe zigzag direction so as to make flat the continuous member orlaminated member.

According to this embodiment, after the forming the folded lines to thebottom portions of the respective valley grooves of the continuousmember or laminated member, the continuous member or laminated member ispressed in the zigzag direction so as to make them flat, so that thecontinuous member or laminated member can be accurately folded into thezigzag form without being formed in a meandering manner, and moreover,the positive electrodes and the negative electrodes can be accuratelyopposed, thus providing an electrode assembly having preferredperformance.

In the above embodiment, the side edges of the continuous member orlaminated member may be pressed in the front end direction of the guidemembers from the time of zigzag-folding the continuous member orlaminated member till the time of withdrawing the guide members.

According to this embodiment, meandering movement of the continuousmember or laminated member at the zigzag-folding time can be prevented,and in addition, at the time of withdrawing the guide members, thecontinuous member or laminated member is not deformed, and accordingly,the electrode assembly can be assembled with high performance.

In the above embodiment, a distance of the continuous member orlaminated member in the zigzag direction may be narrowed after thewithdrawal of the guide members from the respective valley grooves ofthe zigzag-shaped continuous member or laminated member.

According to this embodiment, the opening of each valley groove can bemade large so as to easily insert the positive and negative electrodes,and after the insertion thereof, by narrowing the distance between therespective rows of the guide members, the continuous member or laminatedmember in the zigzag form can be easily made flat.

In a further aspect of the present invention, there is provided anapparatus for manufacturing an electrode assembly for a rectangularbattery in which positive electrodes and negative electrodes arealternately laminated with a separator being interposed therebetween,the apparatus comprising:

a zigzag folding mechanism provided with a plurality of guide membersarranged in zigzag form in a perpendicular direction, and configured tofold a continuous member of the separator into zigzag form, byintersecting rows of the guide members in a horizontal direction whenthe continuous member is inserted between one and another one rows ofthe guide members;

an electrode inserting mechanism for alternately inserting the positiveelectrodes and the negative electrodes in the respective valley groovesof the zigzag-folded continuous member;

a guide member withdrawing mechanism for withdrawing the guide membersfrom the respective valley grooves of the continuous member; and

a press mechanism for pressing the continuous member in the zigzagdirection so as to make flat the continuous member.

According to this aspect, the valley grooves of the numbers necessaryfor one electrode assembly can be simultaneously formed to thecontinuous member of the separator, so that the takt time is remarkablyshortened. In addition, the separator is zigzag-folded by intersectingthe respective rows of the guide members, so that the deep valleygrooves can be formed, and the positive and negative electrodes are madelarge and the electrode assembly having large electric capacity can beprovided. Furthermore, even if the positive and negative electrodes areformed of thin and soft materials, they can be smoothly inserted intothe valley grooves of the separator.

In a further aspect of the present invention, there is also provided anapparatus for manufacturing an electrode assembly for a rectangularbattery in which positive electrodes and negative electrodes arealternately laminated with a separator being interposed therebetween,the apparatus comprising:

a zigzag folding mechanism provided with a plurality of guide membersarranged in zigzag form in a perpendicular direction, and configured tofold a laminated member in which a continuous member of the negativeelectrode is sandwiched between two rows of a continuous member of theseparator into zigzag form, by intersecting rows of the guide members ina horizontal direction when the laminated member is inserted between oneand another one rows of the guide members;

an electrode inserting mechanism for inserting the positive electrodesin the respective valley grooves of the zigzag-folded laminated member;

a guide member withdrawing mechanism for withdrawing the guide membersfrom the respective valley grooves of the laminated member; and

a press mechanism for pressing the laminated member in the zigzagdirection so as to make flat the laminated member.

According to this aspect of the present invention, the valley grooves ofthe numbers necessary for one electrode assembly can be simultaneouslyformed to the laminated member, so that the takt time is remarkablyshortened.

In addition, the electrode assembly having the same layer number as thatof the former embodiment can be formed by the guide members of thenumber less than that of the above aspect, or by using the guide memberof the same number as that of the invention of the above aspect, anelectrode assembly having twice number of layers can be formed.

Furthermore, the laminated member is zigzag-folded by intersecting therows of the guide members, so that the deep valley grooves are formed,and as a result, the positive and negative electrodes having large areacan be provided, and the electrode assembly having large electriccapacity can be also provided.

In a still further aspect of the present invention, there is provided anapparatus for manufacturing an electrode assembly for a rectangularbattery in which positive electrodes and negative electrodes arealternately laminated with a separator being interposed therebetween,the apparatus comprising:

a plurality of guide plates arranged in zigzag form in a perpendiculardirection into two rows, in which the positive electrodes are placed onone row thereof and the negative electrodes are placed on another onerow thereof, and when a continuous member of the separator is insertedbetween the one and another one rows of the guide plates, the respectiverows are intersected with each other in a horizontal direction tothereby fold the continuous member into zigzag form, and the positiveelectrodes and the negative electrodes are alternately inserted into therespective valley grooves of the zigzag-folded continuous member;

an electrode holding mechanism for holding the positive and negativeelectrodes in the respective valley grooves of the continuous member ata time of withdrawing the guide plates from the respective valleygrooves of the continuous member; and

a press mechanism for pressing the continuous member in the zigzagdirection so as to make flat the continuous member.

According to this aspect of the present invention, the valley grooves ofthe numbers necessary for one electrode assembly can be simultaneouslyformed to the continuous member of the separator, so that the takt timeis remarkably shortened. In addition, the separator is zigzag-folded byintersecting the respective rows of the guide members, so that the deepvalley grooves can be formed, and positive and negative electrodes aremade large, and the electrode assembly having large electric capacitycan be provided. Furthermore, even if the positive and negativeelectrodes are formed of thin and soft materials, they can be smoothlyinserted into the valley grooves of the separator.

In addition, since the positive electrodes and the negative electrodesare alternately inserted into the respective valley grooves by theelectrode inserting mechanism while zigzag-folding the continuous memberby intersecting the rows of the guide plates in the horizontaldirection, the zigzag-folding of the continuous member and the insertionof the positive and negative electrodes can be simultaneously performed,so that the structure of the apparatus can be made simple and the takttime can be further shortened.

In a still further aspect of the present invention, there is alsoprovided an apparatus for manufacturing an electrode assembly for arectangular battery in which positive electrodes and negative electrodesare alternately laminated with a separator being interposedtherebetween, the apparatus comprising:

a plurality of guide plates arranged in zigzag form in a perpendiculardirection into two rows, in which the positive electrodes are placed onone and another one rows thereof, and when a laminated member in which acontinuous member of negative electrodes is sandwiched between two rowsof a continuous member of the separator is inserted between the one andanother one rows of the guide plates, the respective rows areintersected with each other in a horizontal direction to thereby foldthe laminated member into zigzag form and the positive electrodes areinserted into the respective valley grooves of the zigzag-foldedlaminated member;

an electrode holding mechanism for holding the positive electrodes inthe respective valley grooves of the laminated member at a time ofwithdrawing the guide plates from the respective valley grooves of thelaminated member; and

a press mechanism for pressing the laminated member in the zigzagdirection so as to make flat the laminated member.

According to this aspect of the present invention, the valley grooves ofthe numbers necessary for one electrode assembly can be simultaneouslyformed to the laminated member, so that the takt time is remarkablyshortened. In addition, the positive electrodes can be inserted into thevalley grooves by the guide plates while zigzag-folding the laminatedmember by intersecting the respective rows of the guide members in thehorizontal direction, so that zigzag-folding of the laminated member andthe insertion of the positive electrodes can be simultaneouslyperformed, thus simplifying the structure of the apparatus and furthershortening the takt time.

In addition, since the laminated member is zigzag-folded by intersectingthe rows of the guide plates, the deep valley grooves can be formed, andthe positive and negative electrodes are made large and the electrodeassembly having large electric capacity can be provided.

In a still further aspect of the present invention, there is provided anapparatus for manufacturing an electrode assembly for a rectangularbattery in which positive electrodes and negative electrodes arealternately laminated with a separator being interposed therebetween,the apparatus comprising:

a zigzag folding mechanism provided with a plurality of guide rodsarranged in zigzag form in a perpendicular direction, and configured tofold a continuous member of the separator by intersecting rows of theguide rods in a horizontal direction when the continuous member isinserted between one and another one rows of the guide rods;

an electrode inserting mechanism for alternately inserting the positiveelectrodes and the negative electrodes in the respective valley groovesof the zigzag-folded continuous member;

a guide rod withdrawing mechanism for withdrawing the guide rods fromthe respective valley grooves of the continuous member; and

a folded line forming mechanism for forming the folded lines to bottomportions of the respective valley grooves of the continuous member afterthe withdrawal of the guide rods; and

a press mechanism for pressing the continuous member, to which thefolded lines are formed, in the zigzag direction so as to make flat thecontinuous member.

According to this aspect of the present invention, the valley grooves ofthe numbers necessary for one electrode assembly can be simultaneouslyformed to the continuous member of the separator, so that the takt timeis remarkably shortened. In addition, the separator is zigzag-folded byintersecting the respective rows of the guide members, so that the deepvalley grooves can be formed, and the positive and negative electrodesare made large and the electrode assembly having large electric capacitycan be provided. Furthermore, even if the positive and negativeelectrodes are formed of thin and soft materials, they can be smoothlyinserted into the valley grooves of the separator.

In addition, since the continuous member is pressed in the zigzagdirection so as to make it flat after the forming of the folded lines tothe bottoms of the respective valley grooves of the continuous member ofthe separator, the continuous member can be folded accurately intozigzag form without being moved in the meandering manner, and moreover,the positive and negative electrodes can be accurately opposed and theelectrode assembly can be manufactured with high performance.

In a still further aspect of the present invention, there is alsoprovided an apparatus for manufacturing an electrode assembly for arectangular battery in which positive electrodes and negative electrodesare alternately laminated with a separator being interposedtherebetween, the apparatus comprising:

a zigzag folding mechanism provided with a plurality of guide rodsarranged in zigzag form in a perpendicular direction, and configured tofold a laminated member, in which a continuous member of the negativeelectrodes are sandwiched between two rows of a continuous member of theseparator, by intersecting rows of the guide rods in a horizontaldirection when the laminated member is inserted between one and anotherone rows of the guide rods;

an electrode inserting mechanism for inserting the positive electrodesin the respective valley grooves of the laminated member when thelaminated member is zigzag-folded;

a guide rod withdrawing mechanism for withdrawing the guide rods fromthe respective valley grooves of the laminated member; and

a folded line forming mechanism for forming the folded lines to bottomportions of the respective valley grooves of the laminated member afterthe withdrawal of the guide rods; and

a press mechanism for pressing the laminated member, to which the foldedlines are formed, in the zigzag direction so as to make flat thelaminated member.

According to this aspect of the present invention, the valley grooves ofthe numbers necessary for one electrode assembly can be simultaneouslyformed to the laminated member, so that the takt time is remarkablyshortened.

In addition, in comparison with the embodiment of the aspect mentionedabove, the electrode assembly having the same number of layers can bemanufactured with the use of reduced number of guide rods, or by usingthe same number of the guide members in the above aspect, the electrodeassembly having the twice layer number can be manufactured in comparisonwith the embodiment of the above aspect of the invention.

Furthermore, since the laminated member is zigzag-folded by intersectingthe rows of the guide rods, the deep valley grooves can be formed, andaccordingly, the positive and negative electrodes are formed so as tohave large areas, thus proving the electrode assembly having largeelectric capacity.

Still furthermore, the positive electrodes are inserted into therespective valley grooves by the electrode inserting mechanism whilezigzag-folding the laminated member by intersecting the rows of theguide rods, so that the takt time can be further shortened. In addition,as mentioned above, in comparison with the above-described invention,the electrode assembly having an increased number of layers can beformed by the reduced number of the guide rods, or the electrodeassembly having twice number of layers can be manufactured by using thesame number of the guide rods.

Furthermore, since the laminated member is made flat by pressing it inthe zigzag direction after the formation of the folded lines to thebottom portions of the respective valley grooves of the laminatedmember, the zigzag-folding can be performed accurately without beingmeandered, and in addition, the positive and negative electrodes can beaccurately opposed and the electrode assembly can be manufactured withhigh performance.

In an embodiment of the above still further aspects of the presentinventions, the electrode inserting mechanism is provided with electrodeconveying trays for inserting the electrodes into the respective valleygrooves of the continuous member or laminated member, and the foldedline forming mechanism is provided with protruded portions formed tofront ends of the respective electrode conveying trays and receivingportions forming the folded lines by clamping the continuous member orlaminated member together with the protruded portions.

According to this embodiment, the insertion of the electrodes into therespective valley grooves of the continuous member or laminated memberand the forming of the folded lines are simultaneously performed, sothat the folded lines can be accurately formed to the groove bottoms ofthe respective valley grooves.

The nature and further characteristic features of the present inventionwill be made clearer from the following description made with referenceto the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 is a perspective view, partially cut away, of a rectangularbattery (or cell) in which an electrode assembly manufactured by methodand apparatus according to the present invention is accommodated;

FIG. 2 is a perspective view showing the electrode assembly manufacturedby the method and apparatus according to a first embodiment of thepresent invention;

FIG. 3 is a schematic perspective view showing an apparatus for carryingout a method according to the first embodiment of the present invention;

FIGS. 4A, 4B and 4C are plan, front and left-side side views,respectively, representing a first step in the method of the firstembodiment of the present invention;

FIGS. 5A, 5B and 5C are plan, front and left-side side views,respectively, representing a second step in the method of the firstembodiment of the present invention;

FIGS. 6A, 6B and 6C are plan, front and left-side side views,respectively, representing a third step in the method of the firstembodiment of the present invention;

FIGS. 7A, 7B and 7C are plan, front and left-side side views,respectively, representing a fourth step in the method of the firstembodiment of the present invention;

FIGS. 8A, 8B and 8C are plan, front and left-side side views,respectively, representing a fifth step in the method of the firstembodiment of the present invention;

FIG. 9 is a perspective view showing the electrode assembly manufacturedby the method and apparatus according to a second embodiment of thepresent invention;

FIG. 10 is a schematic perspective view showing an apparatus forcarrying out a method according to the second embodiment of the presentinvention;

FIGS. 11A, 11B and 11C are perspective views, respectively, showingmodified examples of an electrode conveying tray used in the first andsecond embodiment of the present invention mentioned above;

FIG. 12 is a perspective view showing one example of a pitch changingmember of a guide rod according to a third embodiment of the presentinvention;

FIG. 13A is a front view showing one example of an electrode conveyingtray and a device for driving a push member according to a fourthembodiment of the present invention in a state before a separator isfolded in a zigzag form, FIG. 13B is a front view showing a state inwhich an electrode is inserted into a valley groove after thezigzag-folding of the separator, and FIG. 13C is a front view showing astate in which the electrode is inserted farther deeply in the valleygroove of the separator;

FIG. 14 is a schematic view showing an apparatus for carrying out amethod according to a fifth embodiment of the present invention;

FIGS. 15A, 15B and 15C are plan, front and left-side side views,respectively, representing a first step in the method of the fifthembodiment of the present invention;

FIGS. 16A, 16B and 16C are plan, front and left-side side views,respectively, representing a second step in the method of the fifthembodiment of the present invention;

FIGS. 17A, 17B and 17C are plan, front and left-side side views)respectively, representing a third step in the method of the fifthembodiment of the present invention;

FIG. 18 is a schematic view showing an apparatus for carrying out amethod according to a sixth embodiment of the present invention;

FIG. 19 is a schematic view showing an apparatus for carrying out amethod according to a seventh embodiment of the present invention;

FIGS. 20A, 20B and 20C are plan, front and left-side side views,respectively, representing a first step in the method of the seventhembodiment of the present invention;

FIGS. 21A, 21B and 21C are plan, front and left-side side views,respectively, representing a second step in the method of the seventhembodiment of the present invention;

FIGS. 22A, 22B and 22C are plan, front and left-side side views,respectively, representing a third step in the method of the seventhembodiment of the present invention;

FIGS. 23A, 23B and 23C are plan, front and left-side side views,respectively, representing a fourth step in the method of the seventhembodiment of the present invention;

FIGS. 24A, 24B and 24C are plan, front and left-side side views,respectively, representing a fifth step in the method of the seventhembodiment of the present invention;

FIGS. 25A, 25B and 25C are plan, front and left-side side views,respectively, representing a sixth step in the method of the seventhembodiment of the present invention;

FIG. 26 is a schematic view showing an apparatus for carrying out amethod according to an eighth embodiment of the present invention;

FIG. 27 is a perspective view showing one example of a pitch changingdevice of an electrode conveying tray according to a ninth embodiment ofthe present invention; and

FIG. 28A is a plan view showing another example of a side edge pressingmember used for method and apparatus according to a tenth embodiment ofthe present invention in a state before the separator is folded in azigzag form, FIG. 28B is a plan view showing another example of the sideedge pressing member used for method and apparatus according to thetenth embodiment of the present invention in a state in which anelectrode is inserted into a valley groove after the separator is foldedin the zigzag shape, and FIG. 28C is a front view showing anotherexample of the side edge pressing member used for method and apparatusaccording to the tenth embodiment of the present invention in a state inwhich the guide rods are withdrawn from the valley grooves of theseparator.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention will be describedhereunder with reference to the accompanying drawings. Further, it is tobe noted that terms “right”, “left”, “upper”, “lower” and the like termsare used herein with reference to the illustrated state of the drawingsor in an actual operative state of an apparatus.

First Embodiment

With reference to FIG. 1, reference numeral 1 denotes a rectangular caseof a lithium ion secondary battery, reference numeral 2 denotes anelectrode assembly accommodated in the rectangular case 1. Positiveterminal and negative terminal, both not shown, are provided atpredetermined positions of the rectangular case 1. Electrolyte formed bycombining organic solvent with lithium salt fills in the rectangularcase 1.

The electrode assembly 2 is formed, as shown in FIG. 2, as a laminatedstructure including a continuous member 3 of separator formed in zigzagform (which may be called separator continuous member 3 or merelycontinuous member 3, hereinlater), and positive electrodes 4 andnegative electrodes 5 alternately inserted respectively into valleygrooves 3 a of the continuous member 3. Further, it is to be noted thatthe term “valley grooves 3 a” used herein are portions of the continuousmember 3 of the separator which are formed by folded (bent) bottomportions in shape of grooves of valleys when the continuous member 3 ofthe separator is moved in the zigzag form.

The positive electrodes 4 and the negative electrodes 5 are alternatelylaminated such that each separator is disposed between adjacent positiveelectrode 4 and the negative electrode 5, which are folded into a flatshape. The positive electrode 4 and the negative electrode 5 areprovided with lead portions 4 a and 5 a, respectively, so as to projectin opposing directions from the separator, and the lead portions 4 a and5 a are bundled and connected to the positive and negative batteryterminals (not shown), respectively.

The positive electrode 4 is formed by coating positive electrode activematerial such as lithium transition metal compound oxide on bothsurfaces of sheet-shaped metal foil such as aluminium foil. On the otherhand, the negative electrode 5 is formed by coating negative electrodeactive material such as carbon material on both surfaces of sheet-shapedmetal foil such as copper foil. The continuous member 3 of the separatoris formed from a porous film, to which fine holes are formed, ofsynthetic resin such as polyolefin group resin.

An apparatus for manufacturing the electrode assembly of the structurementioned above will be described hereunder with reference to FIGS. 3 to8.

As shown in FIG. 3, an apparatus for manufacturing the electrodeassembly 2 includes: a zigzag folding mechanism, including a pluralityof guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 jarranged in zigzag form in a perpendicular direction so as to providetwo vertical rows of arrangements as shown, for folding, in zigzag form,the continuous member 3 of the separator by intersecting the rows of theguide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j in thehorizontal direction when the continuous member 3 of the separator isinserted into a space between one and another rows of these guide rods 6a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j: an electrodeinserting mechanism for inserting the positive electrodes 4 and thenegative electrodes 5 alternately in the valley grooves 3 a of thezigzag-folded separator 3, respectively; a guide rod withdrawingmechanism for withdrawing the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6g, 6 h, 6 i and 6 j from the inside of the respective valley grooves 3 aof the continuous member 3 of the separator; and a press mechanism forpressing the continuous member 3 of the separator in the zigzagdirection so as to make flat the same.

The guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j ofthe zigzag folding mechanism are prepared of the numbers same as or morethan the numbers of the positive and negative electrodes 4 and 5supplied to one continuous member 3 of the separator. The guide rods arethen arranged respectively horizontally in two rows in the perpendiculardirection on a base plate 7 so as to provide the zigzag arrangementbetween the respective rows of the guide rods.

As shown in FIGS. 4A, 4B and 4C, the guide rods 6 a, 6 b, 6 c, 6 d, 6 e,6 f, 6 g, 6 h, 6 i and 6 j are supported in cantilever manner byvertical frames 8 and 9 prepared for each row of the guide rods.

The guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j areformed as rollers so as to smoothly fold the continuous member 3 inzigzag shape. Of course, the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6g, 6 h, 6 i and 6 j each having semi-cylindrical shape or round rodseach of which is not rotated may be adopted as far as the guide rods cansmoothly guide the continuous member 3 of the separator.

Each of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6j may be formed with a number of fine nozzles 10 for exhausting air soas to direct to the continuous separator 3 when it is folded in zigzagshape. Each of these nozzles 10 is formed in a desired shape andarrangement such as circular shape or channel shape. By exhausting theair through the nozzles 10, friction between the continuous member 3 andthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j canbe reduced, and the zigzag folding formation of the continuous member 3of the separator can be made further smooth.

Furthermore, a friction reducing material layer, not shown, may beformed on the surface of each of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e,6 f, 6 g, 6 h, 6 i and 6 j as occasion demands. The friction reducingmaterial layer may be formed by coating fluororesin on the guide rodsurface, thereby reducing the friction between the guide rods 6 a, 6 b,6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j and the continuous member 3 ofthe separator, and hence, further smoothing the zigzag-folding formationof the continuous member of the separator.

The zigzag-folding mechanism is provided with a driving unit forintersecting the rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6g, 6 h, 6 i and 6 j and folding the continuous member 3 of the separatorinto zigzag form when the continuous member 3 of the separator isinserted between one and another rows of the guide rods 6 a, 6 b, 6 c, 6d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j. This driving unit is constructedfrom a ball screw, a motor and so on interposed between the base plate 7and the vertical frames 8 and 9 supporting the rows of the guide rods 6a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j. Such driving unitutilizing the ball screw and the motor is a known one, so that it is notshown herein.

On the base plate 7, as shown in FIGS. 6B, 6C and FIGS. 7B, 7C, asurface table 11 for supporting the continuous member 3 of theseparator, which is folded into zigzag form, from the lower side thereofis set to be movable. Further, as shown in FIGS. 4B and 4C, a clamp 12for clamping the base end (lower end as shown) is provided near thesurface table 11 to be movable without interfering the surface table 11.A roll, not shown, on which the continuous member 3 of the separator hasbeen wound up, is provided above the surface table 11. The roll is madeto be less loaded in wind-out direction of the continuous member 3 ofthe separator so as to reduce tension generated to the continuous memberat the portion to be zigzag-folded.

The electrode inserting mechanism is provided with electrode conveyingtrays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j foralternately inserting the positive electrodes 4 and the negativeelectrodes 5 in the respective valley grooves 3 a of the continuousmember 3 of the separator which is folded into zigzag form by the guiderods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j of the zigzagfolding mechanism. The electrode conveying trays 13 a, 13 b, 13 c, 13 d,13 e, 13 f, 13 g, 13 h, 13 i and 13 j are prepared by the same numbersas those of the positive and negative electrodes 4 and 5 necessary forone electrode assembly, and are arranged horizontally behind therespective guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6j.

The electrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g,13 h, 13 i and 13 j are assembled in correspondence with the respectiverows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6j, are supported by vertical frames, not shown, but identical to thoseof the zigzag folding mechanism, and are movable in the horizontaldirection by a driving unit composed of ball screw, not shown, butidentical to that of the zigzag folding mechanism. Although theelectrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13h, 13 i and 13 j may be moved after the zigzag-folding of the continuousmember 3 by the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 iand 6 j, as shown in FIGS. 5A, 5B and 5C, it may be desired that theelectrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13h, 13 i and 13 j at the same time of folding, in the zigzag form, thecontinuous member 3 of the separator intersecting the rows of the guiderods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j. According tosuch operation, the respective positive and negative electrodes 4 and 5can be inserted into the respective valley grooves 3 a of the continuousmember 3 of the separator while performing the zigzag-folding of thecontinuous member 3, thus reducing the takt time.

As shown in FIG. 5C, the electrode conveying trays 13 a, 13 b, 13 c, 13d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j are removed rearward from thevalley grooves 3 a of the continuous member 3 of the separatorimmediately after the insertion of the respective positive and negativeelectrodes 4 and 5 into the valley grooves 3 a of the continuous member3. In order that the electrodes 4 and 5 remain in the valley grooves 3 aof the continuous member 3 at the time when the electrode conveyingtrays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j areretired, as shown in FIGS. 5A, 5B and 5C, pressing members 14, 14 and15, 15 are arranged so as to sandwich the rows of the electrodeconveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and13 j from both the lateral sides thereof. These pressing members 14, 14and 15, 15 are formed as vertical rods abutting against the rear edgesof the positive and negative electrodes 4 and 5 run off or protrudedfrom both the lateral sides of the electrode conveying trays 13 a, 13 b,13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j, and arranged on thelateral portions of the respective rows of the electrode conveying trays13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j. Since thepressing members 14, 14 and 15, 15 are arranged on the rear side of thepositive and negative electrodes 4 and 5 run off from the lateral sidesof the electrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13g, 13 h, 13 i and 13 j, when the electrode conveying trays 13 a, 13 b,13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j are removed rearwardfrom the valley grooves 3 a of the continuous member 3 of the separator,the positive and negative electrodes 4 and 5 remain in the respectivevalley grooves 3 a of the continuous member 3. The pressing members 14,14 and 15, 15 are connected to the base plate 7 through a pistoncylinder assembly, not shown, and when the electrode conveying trays 13a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j move forwardinto the valley grooves 3 a of the continuous member 3, the pressingmembers 14, 14 and 15, 15 are also moved forward by the operation of thepiston cylinder assembly and remain at the forwarded positions after theretirement of the electrode conveying trays 13 a, 13 b, 13 c, 13 d, 13e, 13 f, 13 g, 13 h, 13 i and 13 j outward of the valley grooves 3 a ofthe continuous member 3 of the separator.

As shown in FIG. 3 and FIGS. 5A and 5B, stoppers 16 and 17 are arrangedon both sides in the longitudinal direction of the guide rods 6 a, 6 b,6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j as occasion demands. Thesestoppers 16 and 17 serve to press the positive electrodes 4 and thenegative electrodes 5 inserted into the valley grooves 3 a of thecontinuous member 3 of the separator so as to press the guide rods 6 a,6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j in the longitudinaldirection thereof. The stoppers 16 and 17 are reciprocally movable inthe longitudinal direction of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6f, 6 g, 6 h, 6 i and 6 j by a piston cylinder assembly, not shown, andone of the stoppers 16 is inserted into the respective valleys 3 a ofthe continuous member of the separator by the one of the rows of theelectrode conveying trays 13 a, 13 c, 13 e, 13 g and 13 i and then abutsagainst the side edges of all the positive electrodes 4 which are runoff from the side edge of the separator 3, and on the other hand, theother one of the stoppers 17 is inserted into the respective valleys 3 aof the continuous member 3 of the separator by the other one of the rowsof the electrode conveying trays 13 b, 13 d, 13 f, 13 h and 13 j, andthen abuts against the side edges of all the negative electrodes 5 runoff from the opposing side edge of the separator. According to locationof such stoppers 16 and 17, the positive electrodes 4 and the negativeelectrodes 5 inserted into the valley grooves 3 a of the continuousmember 3 can be accurately positioned in the longitudinal direction ofthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j.

Although not shown, a pitch changing mechanism for narrowing theinterval between the respective guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f,6 g, 6 h, 6 i and 6 j in the row in the longitudinal direction isprovided for each of the respective vertical frames 8 and 9 supportingthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j. Thatis, for the respective vertical frames 8 and 9, there are provided guidegrooves for allowing the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6h, 6 i and 6 j to be slid in the vertical direction thereof andsolenoids for holding the respective guide rods at pitches shown in FIG.3 and FIGS. 5B and 5C. The guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g,6 h, 6 i and 6 j are held by an adsorbing force of the solenoids to thevertical frames 8 and 9 at the pitches shown in FIG. 3 and FIGS. 5B and5C.

When the adsorbing force of the solenoids is released, the respectiveguide rod 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j fall downalong the vertical frames 8 and 9, and the interval in the perpendiculardirection is narrowed as shown in FIGS. 6B and 6C. Accordingly, thecontinuous member 3 of the separator with both the positive and negativeelectrodes 4 and 5 being inserted between the valley grooves 3 a aremade flat in the zigzag direction.

The guide rod 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j can bewithdrawn from the respective valley grooves 3 a of the continuousmember 3 of the separator by the guide rod withdrawing mechanism asshown in FIGS. 7A, 7B, and 7C. The guide rod withdrawing mechanismincludes a piston cylinder assembly, not shown. The piston cylinderassembly is interposed between the base plate 7 and the vertical frames8 and 9 of the guide rod 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and6 j, and according to the expansion/contraction motion of the pistoncylinder assembly, the guide rod 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h,6 i and 6 j are removed out of the respective valleys 3 a of thecontinuous member 3 as shown in FIGS. 7A, 7B and 7C, or are returned tothe positions shown in FIG. 3 and FIGS. 4A, 4B and 4C.

The pressing members 14, 14 and 15, 15 are connected to the base plate 7through the piston cylinder assembly, not shown, as mentioned above.After the guide rod 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 jhave been withdrawn from the respective valley grooves 3 a of thecontinuous member 3 of the separator folded in the zigzag form, when thepiston cylinder assembly is operated, the pressing members 14, 14 and15, 15 are further moved forward as shown in FIGS. 8A, 8B and 8C tothereby push further deeply the positive electrodes 4 and the negativeelectrodes 5 into the valleys 3 a of the separator.

As shown in FIGS. 8A, 8B and 8C, the pressing mechanism includes apusher 18 elevated perpendicularly on the base plate 7. The pusher 18pushes the separator in the zigzag direction so as to make flat thecontinuous member 3 of the separator at the time when the pressingmembers 14, 14 and 15, 15 are moved on the side of the guide rods 6 a, 6b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j, and the positiveelectrodes 4 and the negative electrodes 5 are pushed further deeplyinto the respective valley grooves 3 a. According to such operation, thecontinuous member 3 is made flat so as to provide thickness identical tothat of the electrode assembly 2 shown in FIG. 2 in which the positiveand negative electrodes 4 and 5 are sandwiched by the folded continuousmember 3.

Further, as shown in FIGS. 7A, 7B and 7C, when the guide rods 6 a, 6 b,6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j are withdrawn from the insideof the respective valley grooves 3 a of the continuous member 3 of theseparator, it may be possible to lightly press the continuous member 3in the zigzag direction. According to this operation, the continuousmember 3 of the separator bent in the zigzag form is not deformed inaccordance with the withdrawal of the guide rods 6 a, 6 b, 6 c, 6 d, 6e, 6 f, 6 g, 6 h, 6 i and 6 j.

In the above embodiment, although each of the electrode conveying trays13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j is formedas a horizontal plate, it may be formed, as shown in FIG. 11A, as aelectrode conveying tray 19 formed with a notch into which the stoppercan enter. Further, as shown in FIG. 11B, it may be formed as aelectrode conveying tray having a comb-shaped structure, or as shown inFIG. 11C, it may be also composed of a number of rollers or pins 21arranged on a horizontal plane.

The electrode assembly 2 of the structure mentioned above will bemanufactured in accordance with the following procedures.

(1) As shown in FIG. 3 and FIGS. 4A, 4B, and 4C, the continuous member 3of the separator is inserted between one and the other rows of the guiderods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j arranged in thezigzag form, and then, the front end of the continuous member 3 is heldby the clamp 12. The continuous member 3 is then taken out from a rollaround which the continuous member 3 has been wound up and stretchedbetween the upper and lower guide rods 6 a and 6 j at a small tension.

(2) The rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6i and 6 j are moved in the horizontal direction shown with arrows inFIGS. 4A and 4C, and as shown in FIGS. 5A, 5B and 5C, the rows of theguide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j intersecteach other. According to this operation, the continuous member 3 of theseparator is folded into the zigzag form, and the valley grooves 3 a ofthe numbers required for one electrode assembly 2 are simultaneouslyformed to the continuous member 3 of the separator, thus remarkablyreducing the takt time necessary for the manufacture of the electrodeassembly 2. Furthermore, since the separator is formed into the zigzagshape by intersecting the rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6e, 6 f, 6 g, 6 h, 6 i and 6 j, the deep valley grooves 3 a can becorrespondingly formed, making it possible for large positive electrodes4 and negative electrodes 5 to be inserted, and thus, making it possibleto manufacture the electrode assembly 2 having large capacity.

The guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j areformed as rollers capable of being rotated, so that the tension of thecontinuous member 3 of the separator is relaxed and the continuousmember 3 can be smoothly folded into the zigzag form.

Furthermore, when the rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6f, 6 g, 6 h, 6 i and 6 j intersect each other, air is exhausted from thesurfaces of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 iand 6 j toward the continuous member 3 of the separator through thenozzles 10. According to this operation, at the time when the continuousmember 3 of the separator is folded in the zigzag form, the frictionbetween the continuous member 3 and the guide rods 6 a, 6 b, 6 c, 6 d, 6e, 6 f, 6 g, 6 h, 6 i and 6 j can be reduced, and the tension to beapplied to the continuous member 3 of the separator can be relaxed. As aresult, the time required for the zigzag-folding of the separator 3 canbe shortened and breakage thereof can be suitably prevented.

(3) Simultaneously with the movement of the rows the guide rods 6 a, 6b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j in the horizontal directionshown by arrows in FIGS. 4A and 4C, the electrode conveying trays 13 a,13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j are also movedin the arrowed direction. The positive electrodes 4 are preliminarilyplaced on one of rows of the electrode conveying trays 13 a, 13 c, 13 e,13 g and 13 i and the negative electrodes 5 are also preliminarilyplaced on the other one of rows of the electrode conveying trays 13 b,13 d, 13 f, 13 h and 13 j. Thus, as shown in FIGS. 5A, 5B and 5C, thepositive electrodes 4 and the negative electrodes 5 are alternatelyinserted into the valley grooves 3 a of the zigzag-folded continuousmember 3 of the separator.

As mentioned above, the zigzag-folding of the continuous member 3 of theseparator and the insertion of the positive and negative electrodes 4and 5 can be performed at the same time, while folding the continuousmember 3 by intersecting the rows of the guide rods 6 a, 6 b, 6 c, 6 d,6 e, 6 f, 6 g, 6 h, 6 i and 6 j, and inserting alternately the positiveand negative electrodes 4 and 5 into the valley grooves 3 a of theseparator 3, thus further shortening the takt time.

As shown in FIGS. 5A, 5B and 5C, the pressing members 14, 14 and 15, 15are also moved forward toward the separator and then stopped in thestate of contacting to the rear edges of the positive and negativeelectrodes 4 and 5 placed on the electrode conveying trays 13 a, 13 b,13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j, respectively.

(4) As shown in FIG. 5C with two-dot-chain lines, the electrodeconveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and13 j are returned to the original position immediately after theinsertion of the positive and negative electrodes 4 and 5 into thevalley grooves 3 a of the continuous member 3 of the separator 3.

The pressing members 14, 14 and 15, 15 stop at the advancing positionsand maintain the state abutting against the rear edges of the positiveand negative electrodes 4 and 5. Because of this reason, when theelectrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13h, 13 i and 13 j are retired backward, the positive and negativeelectrodes 4 and 5 are pushed out from surfaces of the electrodeconveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and13 j, and the electrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13f, 13 g, 13 h, 13 i and 13 j are then retired in an empty state with thepositive and negative electrodes 4 and 5 remaining in the valley grooves3 a of the separator.

(5) As shown in FIGS. 5A, 5B and 5C, when the electrode conveying trays13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j, on whichthe positive and negative electrodes 4 and 5 are placed, are invadedinto the valley grooves 3 a of the continuous member of the separator,the respective stoppers 16 and 17 advance in the longitudinal directionof the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j.Thereafter, one of the stoppers 16 is inserted into the respectivevalley grooves 3 a of the separator by one of the rows of the electrodeconveying trays 13 a, 13 c, 13 e, 13 g and 13 i and then contact to theside edges of all the positive electrodes 4 projecting from one sideedge of the separator 3. On the other hand, the other one of thestoppers 17 is inserted into the respective valley grooves 3 a of theseparator by one of the rows of the electrode conveying trays 13 a, 13c, 13 e, 13 g and 13 i and then contact to the side edges of all thenegative electrodes 5 projecting from opposing side edge of theseparator 3. According to such operation, the positive and negativeelectrodes 4 and 5 inserted into the respective valley grooves 3 a ofthe separator can be accurately positioned in the longitudinal directionof the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j.

(6) By the function of the pitch changing mechanism, the respectiveguide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j dropdown, as shown in FIGS. 6A, 6B and 6C, along the vertical frames 8 and 9so as to reduce the interval between the rows of the respective guiderods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j. According tothis operation, the continuous member 3 of the separator, in which thepositive electrodes 4 and the negative electrodes 5 are inserted intothe valley grooves 3 a, respectively, are made flat in the zigzagdirection thereof.

As mentioned above, since the respective guide rods 6 a, 6 b, 6 c, 6 d,6 e, 6 f, 6 g, 6 h, 6 i and 6 j reduce the interval between the rowsthereof after the positive electrodes 4 and the negative electrodes 5have been inserted into the valley grooves 3 a of the separator,openings of the respective valley grooves 3 a are made large to therebyeasily insert the positive and negative electrodes 4 and 5 thereinto,and after the insertion, by reducing the interval between the rows ofthe guide rods the respective guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6g, 6 h, 6 i and 6 j, the zigzag-shaped continuous member 3 of theseparator can be easily made flat.

Further, the pitch changing mechanism may be eliminated in a case wherethe respective guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 iand 6 j are fine ones.

(7) As shown in FIGS. 7A, 7B and 7C, the guide rods 6 a, 6 b, 6 c, 6 d,6 e, 6 f, 6 g, 6 h, 6 i and 6 j are withdrawn from the respective valleygrooves 3 a of the zigzag-shaped separator. At this time, the continuousmember 3 of the separator is slightly pressed in the zigzag direction bythe pusher 18. According to this operation, the deformation of thezigzag-shaped separator 3 due to the withdrawal of the guide rods 6 a, 6b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j can be prevented

(8) As shown in FIGS. 8A, 8B and 8C, when the pressing members 14, 14and 15, 15 advance slightly on the separator side, the positiveelectrodes 4 and the negative electrodes 5 are further deeply pushedinto the valley grooves 3 a of the separator 3. According to thisoperation, the positive electrodes 4 and the negative electrodes 5 aremoved to the positions at which the guide rods 6 a, 6 b, 6 c, 6 d, 6 e,6 f, 6 g, 6 h, 6 i and 6 j exist in the valley grooves 3 a of theseparator, and areas at which the positive electrodes 4 and the negativeelectrodes 5 are overlapped with each other increase, and hence, theelectric capacity is also increased, thereby improving the performanceof the battery. Thus, the separator can be more effectively utilized.

Further, the step of further deeply pushing the positive electrodes 4and the negative electrodes 5 into the valley grooves 3 a may be donejust after the withdrawal of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6f, 6 g, 6 h, 6 i and 6 j from the valley grooves 3 a of thezigzag-shaped continuous member 3, respectively.

(9) As shown in FIGS. 8A, 8B and 8C, in synchronous with the forwardmovement of the pressing members 14, 14 and 15, 15, the pusher 18strongly pushes the continuous member 3 of the separator in the zigzagdirection thereof. According to this operation, the separator is furtherbent and folded in the zigzag form to thereby become further flat, and aflat laminated member in which such flat-shaped continuous member 3 ofthe separator and the positive and negative electrodes 4 and 5 arealternately overlapped can be formed.

(10) When the front end of the separator is released from the clamp 12,and the rear end thereof is cut off from the succeeding continuousseparator 3, the electrode assembly 2 can be completed. The thuscompleted electrode assembly 2 is accommodated in the battery case 1 asshown in FIG. 1.

Second Embodiment

As shown in FIG. 9, an electrode assembly 22 according to this secondembodiment includes a laminated member composed of a continuous member23 folded in zigzag form and the positive electrodes 4 inserted intovalley grooves 3 a of the continuous laminated member 23, respectively.The continuous laminated member 23 is a laminated member composed of tworows of continuous members 3, 3 of the separators and a continuousnegative electrode 24 interposed between the two rows of the separators.According to this structure, the positive electrodes 4 inserted into therespective valley grooves 23 a of the continuous laminated member 23oppose to the continuous negative electrode 24 with the separator beinginterposed therebetween. The positive electrodes 4 and the continuousnegative electrode 24 are provided with lead portions 4 a and 24 a whichare projected from the separator in opposing directions, and these leadportions 4 a and 24 a are bundled respectively, which are then connectedto positive and negative terminals, both not shown, of the battery case1 (shown in FIG. 1)

As shown in FIG. 10, an apparatus for manufacturing the electrodeassembly 22 includes a plurality of guide rods 6 a, 6 b, 6 c, 6 d, 6 e,6 f, 6 g, 6 h, 6 i and 6 j arranged in zigzag form as in the firstembodiment, but in this second embodiment, the continuous laminatedmember 23 is inserted between the two rows of such guide rods 6 a, 6 b,6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j. Further, all the electrodeconveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and13 j convey only the positive electrodes 4 into the valley grooves 23 aof the continuous laminated member 23. Except the above points, theelectrode assembly 22 is manufactured by the similar apparatus andprocesses as those mentioned with reference to the first embodiment.

In this second embodiment, the valleys 23 a for inserting only thepositive electrodes 4 into the continuous laminated member 23 may beformed, so that when the electrode assembly 22 having the sameperformance as that of the electrode assembly 2 in the first embodiment,the numbers of the zigzag-folds can be reduced half in comparison withthe folded numbers of the first embodiment, and accordingly, the numbersof the guide rods and the electrode conveying trays can be also reducedhalf, thus further shortening the takt time.

To the other structures or arrangements, the same reference numerals areadded, in FIGS. 9 and 10, to members or like as those in the firstembodiment, and the duplicated explanations will be omitted herein.

Third Embodiment

In the third embodiment, as shown in FIG. 12, a link mechanism 25 isutilized as the pitch changing mechanism for narrowing the intervalbetween the rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6h, 6 i and 6 j in the perpendicular direction.

This link mechanism is a parallel motion mechanism including a pluralityof members each pivoting links 25 a, 25 a having the same length so asto provide an X-shape, which are connected by means of pins inperpendicular direction. A shaft 26 of the guide rods 6 a, 6 c, 6 e, 6 gand 6 i is inserted into each pivot point of the X-shaped paired links25 a, 25 a, and one end of each of the shafts 26 is inserted into aguide groove 27 a of a guide member 27 extending in the perpendiculardirection. In order to easily hold horizontally the guide rods 6 a, 6 c,6 e, 6 g and 6 i, a plurality of link mechanisms may be arranged in rowsas occasion demands.

Though not shown, substantially identical arrangements of the linkmechanisms and guide member may be made with respect to the opposingguide rods 6 b, 6 d, 6 f, 6 h and 6 j.

According to the arrangement mentioned above, the guide rods 6 a, 6 b, 6c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j are held in the perpendiculardirection at pitches shown in FIG. 3 and FIGS. 5B and 5C, and when thelink mechanism is contracted in the perpendicular direction, the guiderods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j drop downperpendicularly while maintaining the constant interval from each other,and as shown in FIGS. 6B and 6C, the interval in the perpendiculardirection is narrowed. As a result, the zigzag-shaped continuous member3 having the valley grooves 3 a into which the positive and negativeelectrodes 4 and 5 are inserted are made flat to thereby provide anelectrode assembly 2.

Fourth Embodiment

In this fourth embodiment, as shown in FIGS. 13A, 13B and 13C, theelectrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13h, 13 i and 13 j are assembled in correspondence with the respectiverows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6j, and the rear ends of the respective trays are connected to thevertical frames 28.

The vertical frames 28, 28 are connected to the piston rods 29 a, 29 aof the piston cylinder assemblies 29, 29 which are expanded andcontracted in the conveying direction of the respective electrodes 4 and5, and the respective piston cylinder assemblies 29, 29 are placed on areciprocal table 30, 30 to be reciprocally movable in the conveyingdirection of the respective electrodes 4 and 5.

Each of the reciprocal tables 30 (refer to FIGS. 3 and 10) is connectedto a nut 32 screwed with a ball screw 31 as feed screw means mounted onthe base plate 7 to be rotatable. The ball screw 31 is rotated by meansof motor, not shown.

The pressing members 14, 14 and 15, 15 are mounted to the reciprocaltables 30, 30, and when the reciprocal tables 30, 30 are moved by therotation of the ball screws 31, 31, the pressing members 14, 14 and 15,15 are moved together with the electrode conveying trays 13 a, 13 b, 13c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j. When the piston cylinderassemblies 29, 29 are expanded and contracted, the electrode conveyingtrays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 jperform the reciprocal movement independently of the pressing members14, 14 and 15, 15.

The functions of the electrode assembly manufacturing apparatus of thepresent invention of the characters mentioned above will be describedhereunder.

(1) In the state shown in FIG. 13A, the respective rows of the guiderods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j start to movein the horizontal direction as shown with arrows as like as in the firstembodiment. At the same time, the ball screws 31, 31 take one turn inone direction, and the electrode conveying trays 13 a, 13 b, 13 c, 13 d,13 e, 13 f, 13 g, 13 h, 13 i and 13 j and the pressing members 14, 14and 15, 15 on the respective reciprocal tables 30, 30 are movedintegrally in the arrowed direction with respect to each of the lateralelectrode assembly.

At this time, the positive electrodes 4 are preliminarily placed on theone of the rows of the electrode conveying trays 13 a, 13 c, 13 e, 13 gand 13 i and on the other hand, the negative electrodes 5 arepreliminarily placed on the other one of the rows of the electrodeconveying trays 13 b, 13 d, 13 f, 13 h and 13 j.

(2) As shown in FIG. 13B, when the respective rows of the guide rods 6a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j intersect with eachother, the continuous member 3 of the separator is folded into zigzagform. Further, when the lateral reciprocal tables 30, 30 approach eachother, the positive electrodes 4 and the negative electrodes 5 arealternately inserted into the respective valley grooves 3 a of theseparator, and the reciprocal tables 30, 30 stop at a time when therespective front ends of the electrode conveying trays 13 a, 13 b, 13 c,13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j approach the guide rods 6 a,6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j, respectively.

The pressing members 14, 14 and 15, 15 also advance on the separatorside and then stop together with the electrode conveying trays 13 a, 13b, 13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j in a state that thepressing members are in contact with the rear edges of the positive andnegative electrodes 4 and 5 on the electrode conveying trays 13 a, 13 b,13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j.

(3) When the electrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13f, 13 g, 13 h, 13 i and 13 j on which the positive and negativeelectrodes 4 and 5 are placed invade into the valley grooves 3 a of theseparator, as like as in the first and second embodiments, therespective stoppers 16 and 17 advance in the longitudinal direction ofthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j.Then, one of the stoppers 16 is inserted into the respective valleygrooves 3 a of the separator by one row of the electrode conveying trays13 a, 13 c, 13 e, 13 g and 13 i and abuts against the side edges of allthe positive electrodes 4 projecting over the side edge of theseparator. On the other hand, the other one of the stoppers 17 isinserted into the respective valley grooves 3 a of the separator by onerow of the electrode conveying trays 13 b, 13 d, 13 f, 13 h and 13 j andabuts against the side edges of all the negative electrodes 5 projectingover the side edge of the separator.

According to such operation, the positive electrodes 4 and the negativeelectrodes 5 inserted into the respective valley grooves 3 a of thecontinuous member 3 of the separator are positioned exactly in thelongitudinal direction of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6g, 6 h, 6 i and 6 j. These stoppers 16 and 17 may be provided asoccasion demands.

(4) Thereafter, as shown in FIG. 13C, the piston cylinder assemblies 29,29 placed on the reciprocal tables 30, 30 are contracted, and then, theelectrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f, 13 g, 13h, 13 i and 13 j are removed out of the valley grooves 3 a of theseparator and retired to the position shown with the solid line in FIG.13C.

At that time, the pressing members 14, 14 and 15, 15 keep the forwardingpositions shown in FIG. 13B and maintain the state abutting against therear edges of the positive and negative electrodes 4 and 5. Because ofthis reason, the positive and negative electrodes 4 and 5 are pushed outfrom the electrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13 f,13 g, 13 h, 13 i and 13 j when the electrode conveying trays 13 a, 13 b,13 c, 13 d, 13 e, 13 f, 13 g, 13 h, 13 i and 13 j are moved rearward,and then, the electrode conveying trays 13 a, 13 b, 13 c, 13 d, 13 e, 13f, 13 g, 13 h, 13 i and 13 j are retired in the empty state with thepositive and negative electrodes 4 and 5 remaining in the valley grooves3 a of the separator.

(5) As occasion demands, as like as in the first, second and thirdembodiments, the pitch changing mechanism is provided, and according tothe function thereof, the interval between the respective rows of theguide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j arenarrowed.

(6) As shown in FIG. 13C, the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6g, 6 h, 6 i and 6 j are withdrawn from the respective valley grooves 3 aof the zigzag-shaped continuous member 3 of the separator.

(7) When the guide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and6 j are withdrawn, as shown in FIG. 13C, the ball screws 31, 31 arerotated to move slightly forward the pressing members 14, 14 and 15, 15toward the separator side to thereby push further deeply the positiveand negative electrodes 4 and 5 into the valley grooves 3 a of theseparator, respectively.

According to these motions, the positive electrodes 4 and the negativeelectrodes 5 are moved with high accuracy to the position in which theguide rods 6 a, 6 b, 6 c, 6 d, 6 e, 6 f, 6 g, 6 h, 6 i and 6 j in therespective valley grooves 3 a of the separator 3 exist, and then, thepositive electrodes 4 and the negative electrodes 5 are overlappedaccurately, thus increasing the electric capacity, and hence, improvingthe performance as the battery. The separator can be more effectivelyutilized.

(8) Thereafter, as in the first embodiment, the separator is folded intofurther flat, and the electrode assembly 2 as the flat laminated memberincluding the overlapped flat separator and the positive and negativeelectrodes 4 and 5 is formed.

Further, it is to be noted that like reference numerals are added toportions or members shown in FIGS. 13A, 13B and 13C corresponding tothose in the first embodiment, and duplicated explanation is omittedherein.

Fifth Embodiment

A electrode assembly manufacturing apparatus according to the fifthembodiment will be explained hereunder with reference to FIGS. 14 to 17for manufacturing the electrode assembly shown in FIG. 2.

As shown in FIG. 14, the electrode assembly manufacturing apparatus ofthis embodiment is provided with: a plurality of guide plates 113 a, 113b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j includingtwo rows arranged in a perpendicular direction in the zigzag form, inwhich on the one row of the guide plates, the positive electrodes 4 areplaced, and on the other row thereof, the negative electrodes 5 areplaced, and when the continuous member 3 of the separator is insertedbetween these two rows, the continuous member 3 is moved and intersecthorizontally to thereby fold the same into zigzag-shape; an electrodeholding mechanism for holding the positive electrodes 4 and the negativeelectrodes 5 in the respective valley grooves 3 a of the continuousmember 3 when the guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f,113 g, 113 h, 113 i and 113 j are withdrawn from the respective valleygrooves 3 a; and a pressing mechanism for pressing the continuous member3 in the zigzag direction to make flat the continuous member 3 of theseparator.

A plurality of guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f,113 g, 113 h, 113 i and 113 j are prepared by the numbers same as ormore than the numbers of the positive and negative electrodes 4 and 5supplied to one row of the continuous member 3 of the separator. Theguide plates are then arranged horizontally at respective two rows inthe perpendicular direction on the base plate 107 so as to provide thezigzag shape between these rows.

As shown in FIG. 14 and FIGS. 15A to 15C, the guide plates 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j are formed toan inclining plate gently inclining toward the front ends of theintersecting side (intersecting side front ends, hereinlatter) by movingthem horizontally between the rows.

Rotatable rollers 106 a, 106 b, 106 c, 106 d, 106 e, 106 f, 106 g, 106h, 106 i and 106 j are mounted to the intersecting side front ends ofthe guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h,113 i and 113 j so as to smoothly fold the continuous member 3 of theseparator in the zigzag form. That is, each of these rollers 106 a, 106b, 106 c, 106 d, 106 e, 106 f, 106 g, 106 h, 106 i and 106 j has alength substantially the same as the width of each of the guide plates113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j,and the both ends of each roller is mounted to be rotatable by a supportarm, not shown, secured to a portion near the front end of the guideplate. Further, each of the respective rollers 106 a, 106 b, 106 c, 106d, 106 e, 106 f, 106 g, 106 h, 106 i and 106 j may have asemi-cylindrical shape or may be non-rotatable round bar, not acylindrical shape, as far as it can smoothly guide the continuous member3 of the separator.

A number of ejecting ports, not shown, through which air is jettedtoward the continuous member 3 when the continuous member 3 is foldedinto the zigzag form, may be formed as occasion demands to each of therespective rollers 106 a, 106 b, 106 c, 106 d, 106 e, 106 f, 106 g, 106h, 106 i and 106 j of the guide plates 113 a, 113 b, 113 c, 113 d, 113e, 113 f, 113 g, 113 h, 113 i and 113 j. The ejecting ports may beformed in a desired shape or arrangement such as circular shape orgroove arrangement. When the air is jetted through these ports, thefriction between the continuous member 3 and the guide plates 113 a, 113b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j arereduced, and the zigzag folding of the continuous separator 3 can befurther made smooth.

Furthermore, on the surfaces of the respective rollers 106 a, 106 b, 106c, 106 d, 106 e, 106 f, 106 g, 106 h, 106 i and 106 j, friction reducinglayers (films), not shown, may be formed as occasion demands. Thefriction reducing layer is formed by coating fluororesin. Accordingly,the friction between the respective rollers 106 a, 106 b, 106 c, 106 d,106 e, 106 f, 106 g, 106 h, 106 i and 106 j and the continuous member 3of the separator is reduced, and the zigzag folding of the continuousmember 3 can be made smooth. Furthermore, on the surfaces of the guideplates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and113 j, such friction reducing layers may be also formed as occasiondemands.

The guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h,113 i and 113 j are provided with a driving unit for folding thecontinuous member of the separator into the zigzag form by intersectingthe two rows of the guide plates when the continuous member 3 of theseparator is inserted between the respective rows of the guide plates113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j.This guide unit is composed of a ball screw and a motor for rotating theball screw, or piston cylinder assembly disposed between the frame, notshown, supporting the rows of the guide plates and the base plate 107.The drive unit composed of such ball screw and the motor, or the pistoncylinder assembly is known means, so that the detailed structure thereofis not shown herein.

On the base plate 107, as shown in FIGS. 17B and 17C, a surface table111 for receiving the zigzag folded continuous member 3 of the separatorfrom the lower side thereof is mounted to be movable. Furthermore, asshown in FIGS. 15B and 15C, a clamp 112 for holding the base end of thecontinuous member 3 of the separator is also mounted at a portion nearthe surface table 111 so as not to interfere the surface table 111. Aroll, not shown, around which the continuous member 3 of the separatoris wound up is provided above the surface table 111. The roll has astructure so as not to be largely loaded in the wind-out direction ofthe continuous member 3 and so as to reduce tension caused to thecontinuous member 3 at a portion to be zigzag-folded.

The guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h,113 i and 113 j serve to insert the positive electrodes 4 and thenegative electrodes 5 alternately into the respective valley grooves 3 aof the continuous member 3 of the separator while folding the separatorinto the zigzag form.

More specifically, as shown in FIG. 16C, the guide plates 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j are removedrearward from the valley grooves 3 a of the continuous member 3immediately after the insertion of the positive electrodes 4 and thenegative electrodes 5 into the valley grooves 3 a. At the time of therearward removal of the guide plates 113 a, 113 b, 113 c, 113 d, 113 e,113 f, 113 g, 113 h, 113 i and 113 j, in order that the positive andnegative electrodes 4 and 5 remain in the valley grooves 3 a of thecontinuous member 3 of the separator, as shown in FIGS. 14 to 16 (FIGS.16A to 16C), pressing members 114, 114 and 115, 115 as electrode holdingmechanism are arranged so as to sandwich the rows of the guide plate 113a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j fromboth the lateral sides thereof. These pressing members 114, 114 and 115,115 are formed as vertical rods abutting against the rear edges of thepositive and negative electrodes 4 and 5 run off (projected over) fromboth the lateral sides of the guide plates 113 a, 113 b, 113 c, 113 d,113 e, 113 f, 113 g, 113 h, 113 i and 113 j, and arranged laterally ofthe respective rows of the guide plates 113 a, 113 b, 113 c, 113 d, 113e, 113 f, 113 g, 113 h, 113 i and 113 j. According to the arrangement inwhich the pressing members 114, 114 and 115, 115 are disposed rearwardof the positive and negative electrodes 4 and 5 run off from both thelateral sides of the guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113f, 113 g, 113 h, 113 i and 113 j, when the guide plates 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j are removedrearward from the valley grooves 3 a of the continuous member 3 of theseparator, the positive and negative electrodes 4 and 5 remain in therespective valley grooves 3 a on the separator side. The pressingmembers 114, 114 and 115, 115 are connected to the base plate 107through the ball screw and the motor for rotating the ball screw, or thepiston cylinder assembly, not shown, and when the guide plates 113 a,113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j advanceinto the valley grooves 3 a of the continuous member 3 of the separator,the pressing members 114, 114 and 115, 115 also advance by the operationof the piston cylinder assembly or the combination of the ball screw andthe motor for rotating the ball screw, and retains at that positionafter the rearward movement of the guide plates 113 a, 113 b, 113 c, 113d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j outside the valleygrooves 3 a of the continuous member 3 of the separator.

As shown in FIG. 14 and FIGS. 16A and 16B, stoppers 116 and 117 forpressing the positive electrodes 4 and the negative electrodes 5inserted into the respective valley grooves 3 a of the continuous memberof the separator in the width direction of the guide plates 113 a, 113b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j areprovided, as occasion demands, on both sides in the width direction ofthe guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h,113 i and 113 j. The respective stoppers 116 and 117 are formed to bereciprocally movable with respect to the width direction of the guideplates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and113 j by the piston cylinder assembly, not shown. One of the stoppers116 is inserted into the respective valley grooves 3 a of the continuousmember 3 of the separator by one of rows of the guide plates 113 a, 113c, 113 e, 113 g and 113 i and abuts against all the positive electrodes4 run off from the side edge of the separator, and the other one of thestoppers 117 is inserted into the respective valley grooves 3 a of thecontinuous member 3 of the separator by the other one of rows of theguide plates 113 b, 113 d, 113 f, 113 h and 113 j and abuts against allthe negative electrodes 5 run off from the opposing side edge of theseparator. The positive electrodes 4 and the negative electrodes 5inserted into the respective valley grooves 3 a of the continuous member3 of the separator are accurately positioned in the width direction ofthe guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h,113 i and 113 j.

The guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h,113 i and 113 j may be withdrawn from the respective valley grooves 3 aof the continuous member 3 of the separator, as shown in FIGS. 16A to16C, by the guide plate withdrawing mechanism. The guide platewithdrawing mechanism is composed of, for example, a piston cylinderassembly, though not shown, (or ball screw and motor for rotating theball screw). This piston cylinder assembly is interposed between thebase plate 107 and the vertical frame, not shown, of the 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j, and accordingto the expansion/contraction motion of the piston cylinder assembly, theguide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113i and 113 j are removed outside the valley grooves 3 a of the separator,as shown in FIG. 16A to 16C, or returned to the positions shown in FIG.14 or FIGS. 15A to 15C.

The pressing members 114, 114 and 115, 115 are connected to the baseplate 107 though the combination of ball screw and motor for rotatingthe ball screw, or piston cylinder assembly, not shown, as mentionedabove. After the withdrawn of the guide plates 113 a, 113 b, 113 c, 113d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j from the inside of thevalley grooves 3 a of the continuous member 3 of the separator foldedinto zigzag shape, the pressing members 114, 114 and 115, 115 furtheradvance as shown in FIGS. 16A to 16C by the operation of the ball screwand the motor for rotating the ball screw, or the piston cylinderassembly to thereby further deeply insert the positive electrodes 4 andthe negative electrodes 5 into the respective valley grooves 3 a of theseparator 3.

As shown in FIGS. 17A to 17C, the pressing mechanism is formed as apusher 118 capable of being movable in the perpendicular direction onthe base plate 107. The pusher 118 serves to press and make flat thecontinuous member 3 of the separator in the zigzag direction at the timewhen the pressing members 114, 114 and 115, 115 further advance on theside of the guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113g, 113 h, 113 i and 113 j, and the positive electrodes 4 and thenegative electrodes 5 are pushed further deeply into the respectivevalley grooves 3 a. According to such operation, the separator is madeflat to the extent of the thickness of the electrode assembly 2 shown inFIG. 2 in which the positive and negative electrodes 4 and 5 aresandwiched between the continuous member 3 of the separator.

Further, as shown in FIGS. 17A to 17C, the continuous member 3 may bepushed at a small force in the zigzag direction at the time when theguide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113i and 113 j are withdrawn from the inside of the valley grooves 3 a ofthe separator 3. According to such operation, the continuous member 3bent in the zigzag form may be destroyed at the time of withdrawing the113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j.

The electrode assembly 2 mentioned above will be manufactured by themanufacturing apparatus of the structure mentioned above according tothe following procedure.

(1) As shown in FIG. 14 and FIGS. 15A to 15C, the continuous member 3 ofthe separator is inserted between the one and other rows of the guideplates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and113 j arranged in the zigzag form, and the front end of this continuousmember 3 is held by the clamp 112. The continuous member 3 is paid outfrom the roll on which the continuous member 3 has been wound up, andstretched between the upper and lower guide plates 113 a and 113 j at asmall tension.

(2) Then, the rows of the guide plates 113 a, 113 b, 113 c, 113 d, 113e, 113 f, 113 g, 113 h, 113 i and 113 j are moved in the horizontaldirection as shown with arrows in FIGS. 15A to 15C, and as shown inFIGS. 16A to 16C, the rows of the guide plates 113 a, 113 b, 113 c, 113d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j intersect with eachother. Accordingly, while folding the continuous member 3 of theseparator into zigzag form, the valley grooves 3 a of the numbernecessary for one electrode assembly 2 are simultaneously formed to thecontinuous member 3 of the separator, and hence, the takt time necessaryfor the manufacture of the electrode assembly 2 can be remarkablyreduced. Furthermore, since the separator is folded into zigzag form byintersecting the respective rows of the guide plates 113 a, 113 b, 113c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j, the deep valleygrooves 3 a can be formed, which allows the large positive and negativeelectrodes 4 and 5 to be inserted thereinto, and the electrode assembly2 having large electric capacity can be manufactured.

Furthermore, since the rotatable rollers 106 a, 106 b, 106 c, 106 d, 106e, 106 f, 106 g, 106 h, 106 i and 106 j are mounted to the intersectingside front ends of the guide plates 113 a, 113 b, 113 c, 113 d, 113 e,113 f, 113 g, 113 h, 113 i and 113 j, respectively, the tension of theseparator can be relaxed and the separator can be smoothly folded intozigzag form.

Furthermore, at the time when the rows of the guide plates 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j intersect witheach other, air is jetted through the ejecting ports formed in thesurface of the rollers 106 a, 106 b, 106 c, 106 d, 106 e, 106 f, 106 g,106 h, 106 i and 106 j toward the continuous member 3 of the separator.According to this operation, at the time of folding the continuousmember 3 of the separator into zigzag form, the friction between thecontinuous member 3 of the separator and the guide plates 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j is reduced,the time required for folding the separator into zigzag form can beshortened, and the continuous member 3 can be properly prevented frombeing broken.

(3) When the rows of the guide plates 113 a, 113 b, 113 c, 113 d, 113 e,113 f, 113 g, 113 h, 113 i and 113 j are moved in the horizontaldirection as shown with arrows in FIGS. 15A and 15C, the positiveelectrodes 4 are preliminarily placed on one of the rows of the guideplates 113 a, 113 c, 113 e, 113 g and 113 i and on the other hand, thenegative electrodes 5 are also preliminarily placed on the other one ofthe rows of the guide plates 113 b, 113 d, 113 f, 113 h and 113 j.Accordingly, as shown in FIGS. 16A to 16C, the positive electrodes 4 andthe negative electrodes 5 are alternately inserted into the valleygrooves 3 a of the continuous member 3 of the separator, which is foldedinto zigzag form.

As mentioned above, the zigzag-folding of the continuous member 3 of theseparator and the insertion of the positive and negative electrodes 4and 5 can be simultaneously performed by alternately inserting thepositive electrodes 4 and the negative electrodes 5 in the respectivevalley grooves 3 a while folding the continuous member 3 in the zigzagform by intersecting the respective rows of the guide plates 113 a, 113b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j with eachother, thus simplifying the structure of the apparatus and shorteningthe takt time.

As shown in FIGS. 16A to 16C, the pressing members 114, 114 and 115, 115advance on the separator side and stop there in the state of contactingto the rear edges of the positive and negative electrodes 4 and 5 placedon the guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113h, 113 i and 113 j.

(4) Next, as shown with two-dot-chain line in FIG. 16C, the guide plates113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 jreturn back to the original position immediately after the insertion ofthe positive and negative electrodes 4 and 5 into the valley grooves 3 aof the separator. Herein, since the guide plates 113 a, 113 b, 113 c,113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j are formed to aninclining plate inclining to the front end on the intersecting sidethereof, the guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113g, 113 h, 113 i and 113 j can be easily inserted into and withdrawn fromthe respective valley grooves 3 a of the separator, thus reducing thetime necessary for folding the continuous member 3 of the separator.

The pressing members 114, 114 and 115, 115 stop at the advancingposition and maintain the condition abutting against the rear edges ofthe positive and negative electrodes 4 and 5. Accordingly, the positiveand negative electrodes 4 and 5 are pushed out from the upper portion ofthe guide plates 113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h,113 i and 113 j at the retiring time of the guide plates 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j. Thus, at thistime, the guide plates are retired in an empty state, and the positiveand negative electrodes 4 and 5 remain in the valley grooves 3 a of theseparator.

(5) As shown in FIGS. 16A to 16C, when the guide plates 113 a, 113 b,113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j, on which thepositive and negative electrodes 4 and 5 are placed, invade into thevalley grooves 3 a of the separator, the respective stoppers 116 and 117advance toward the width direction of the guide plates 113 a, 113 b, 113c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j. Then, one of thestoppers 116 is inserted into the respective valley grooves 3 a of theseparator by one row of the guide plates 113 a, 113 c, 113 e, 113 g and113 i and abut against the side edges of all the positive electrodes 4projecting over the side edge of the separator. On the other hand, theother one of the stoppers 117 is inserted into the respective valleygrooves 3 a of the separator by the other one row of the guide plates113 b, 113 d, 113 f, 113 h and 113 j, and abut against the side edges ofall the negative electrodes 5 projecting over the opposing side edge ofthe separator. According to such operation, the positive electrodes 4and the negative electrodes 5 inserted into the respective valleygrooves 3 a of the continuous member 3 of the separator can beaccurately positioned in the width direction of the guide plates 113 a,113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j.

(6) Furthermore, as shown in FIGS. 16A to 16C, the guide plates 113 a,113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j arewithdrawn from the respective valley grooves 3 a of the zigzag-shapedcontinuous member 3 of the separator. At this time, the continuousmember 3 is lightly pushed in the zigzag direction by the pusher 118,thereby preventing the continuous member 3 of the separator fromdestroying in shape at the time of the withdrawal of the guide plates113 a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 j.

(7) Still furthermore, as shown in FIGS. 16A to 16C, the pressingmembers 114, 114 and 115, 115 slightly advance on the separator side,and the positive and negative electrodes 4 and 5 are pushed furtherdeeply into the respective valley grooves 3 a of the separator. Then,the positive and negative electrodes 4 and 5 are moved to the positionsin the valley grooves 3 a of the separator at which the guide plates 113a, 113 b, 113 c, 113 d, 113 e, 113 f, 113 g, 113 h, 113 i and 113 jexisted, and an overlapped area of the positive electrodes 4 and thenegative electrodes 5 increases. Thus, the electric capacity can beincreased, and the performance as battery can be improved. The separatorcan be more effectively used.

The step of pushing the positive and negative electrodes 4 and 5 furtherdeeply into the respective valley grooves 3 a may be carried out afterthe withdrawal of the guide plates 113 a, 113 b, 113 c, 113 d, 113 e,113 f, 113 g, 113 h, 113 i and 113 j from the respective valley grooves3 a of the zigzag-shaped continuous member 3 of the separator.

(8) As shown in FIGS. 17A to 17C, the pusher 118 strongly pushes thecontinuous member 3 in the zigzag direction in synchronism with theadvancing of the pressing members 114, 114, and 115, 115. According tothis motion, the zigzag-shaped bent portion of the separator is foldedand further made flat, and this flat separator and the positive andnegative electrodes 4 and 5 are overlapped to thereby provide a flatlamination structure.

(9) The front end of the separator is released from the clamp 112, andthe rear end thereof is cut off so as to separate from the separator,thus completing the electrode assembly 2 shown in FIG. 2, which isaccommodated in the battery case 1 as shown in FIG. 1.

Sixth Embodiment

This sixth embodiment explains the manufacture of the electrode assembly22 shown in FIG. 9.

As shown in FIG. 18, an apparatus for manufacturing the electrodeassembly 22 is similar to that of the fifth embodiment having aplurality of guide plates 113 a, 113 b, 113 c, 113 d, 113 e and 113 farranged in the zigzag form and other structures, but between one andthe other one rows of the guide plates 113 a, 113 b, 113 c, 113 d, 113 eand 113 f, a continuous laminated member 23 is inserted. Further, allthe guide plates 113 a, 113 b, 113 c, 113 d, 113 e and 113 f serve toconvey only the positive electrodes 4 into the valley grooves 23 a ofthe laminated member 23. Except the above structures, the electrodeassembly 22 may be manufactured by the apparatus and method similar tothose mentioned with respect to the fifth embodiment.

In this sixth embodiment, since the valley groove 23 a for insertingonly the positive electrodes 4 into the laminated member 23 may beformed, when it is required to manufacture the electrode assembly 22 ofthe same performance as that of the electrode assembly 2 of the fifthembodiment, the folding number of the laminated member 23 can be reducedhalf, and accordingly, the number of the guide plates 113 a, 113 b, 113c, 113 d, 113 e and 113 f can be also made half, thus further reducingthe takt time.

The description of the structures and functions of the sixth embodimentsubstantially the same as those of the fifth embodiment may be omittedherein.

Seventh Embodiment

This seventh embodiment explains an apparatus for manufacturing theelectrode assembly 2 shown in FIG. 2 with reference to FIGS. 19 to 25.

As shown in FIG. 19, the apparatus for manufacturing the electrodeassembly 2 is provided with a surface table 212 on a base plate, notshown. The surface table 212 is, as shown in FIGS. 21B and 21C, placedbelow the continuous member 3 of the separator which is folded intozigzag form. Further, as shown in FIGS. 20B and 20C, a clamp 212 aclamping the base end of the continuous member 3 of the separator isdisposed at a portion near the one side of the surface table 212 so asnot to interfere with the surface table 212. Above the surface table212, as shown in FIG. 20C, there is disposed a roll 3 b around which thecontinuous member 3 of the separator is wound up. The roll 3 is disposedso as not to be loaded in the wind-off direction of the continuousmember 3 and so as to reduce a tension caused to a portion of thecontinuous member to be zigzag-folded. Furthermore, a cutter 233 isarranged on a travelling path of the continuous member 3 of theseparator so as to cut the separator continuous member 3 wound-off fromthe roll 3 b at a predetermined portion.

As shown in FIG. 19, the apparatus for manufacturing the electrodeassembly 2 is provided with: a zigzag folding mechanism for folding thecontinuous member 3 of the separator by intersecting the rows of theseguide rods in the horizontal direction at a time when the continuousmember 3 of the separator is inserted between the one and the other onerows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7e, 7 f, the zigzag folding mechanism is provided with a plurality ofguide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 farranged in the zigzag form in the perpendicular direction; an electrodeinsertion mechanism for alternately inserting the positive and negativeelectrodes 4 and 5 into the respective valley grooves 3 a of theseparator (see FIG. 2) at the time when the continuous member 3 of theseparator is folded into the zigzag form; a guide rod withdrawingmechanism for withdrawing the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7a, 7 b, 7 c, 7 d, 7 e, 7 f from the respective valley grooves 3 a of theseparator; a side edge pressing mechanism for pressing the side edges 3c, 3 c of the continuous member 3 of the separator in the front enddirection of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7d, 7 e, 7 f till the time of withdrawing the guide rods 6 a, 6 b, 6 c, 6d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f from the time of folding thecontinuous member 3 of the separator; a folding line forming mechanismfor forming folding lines 234 (see FIG. 23C) to the bottom portions ofthe valley grooves 3 a of the separator continuous member 3 after thewithdrawal of the guide rods 6 a, 6 b, 6 e, 6 d, 6 e and 7 a, 7 b, 7 c,7 d, 7 e, 7 f, and a press mechanism for pressing the continuous member3 of the separator with the folded lines 234 into the zigzag directionso as to make flat the continuous member 3.

The number of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c,7 d, 7 e, 7 f of the zigzag folding mechanism is the same as or morethan the number of the positive and negative electrodes 4 and 5 suppliedwith respect to one continuous member 3 of the separator, and theseguide rods are arranged in two rows in the perpendicular direction onthe upper side of the surface table 212 in a zigzag arrangement.

As shown in FIGS. 20A to 20C, the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and7 a, 7 b, 7 c, 7 d, 7 e, 7 f are supported in a cantilever manner to thevertical frames 208 and 209 for the respective rows of the guide rods.

The guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 fmay be formed as rotatable rollers so as to smoothly fold the continuousmember 3 of the separator into the zigzag form. Of course, each of theguide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f mayhave semi-cylindrical shape (not a cylindrical shape) or round-rod shapewhich is not rotated, as far as the guide rods 6 a, 6 b, 6 c, 6 d, 6 eand 7 a, 7 b, 7 c, 7 d, 7 e, 7 f can smoothly guide the continuousmember 3 of the separator.

A number of fine nozzles 10 for jetting air toward the continuous member3 of the separator when the continuous member 3 is folded into thezigzag form are formed, as occasion demands, to the guide rods 6 a, 6 b,6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f. Each of the nozzles 10has a desired shape such as circular shape, groove shape or like, and anumber of such nozzles are formed in a desired arrangement. When the airjetted through the fine nozzles 10, the friction between the continuousmember 3 of the separator and the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and7 a, 7 b, 7 c, 7 d, 7 e, 7 f is reduced, and the zigzag-folding of thecontinuous member 3 can be further smoothly performed.

Furthermore, a friction reducing layer, not shown, is formed, asoccasion demands, on the surface of the guide rods 6 a, 6 b, 6 c, 6 d, 6e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f. The friction reducing layer isformed by coating fluororesin or like. According to this coating of thefriction reducing layer, the friction between the guide rods 6 a, 6 b, 6c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f and the continuous member 3of the separator can be reduced, and the zigzag-folding of thecontinuous member 3 can be smoothly made.

The zigzag-folding mechanism is provided with a driving member forzigzag-folding the continuous member 3 of the separator by intersectingthe respective rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7b, 7 c, 7 d, 7 e, 7 f when the continuous member 3 of the separator isinserted into one and the other one of rows of the guide rods 6 a, 6 b,6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f. This driving member iscomposed of a ball screw interposed between the vertical frames 208 and209 supporting the respective rows of the guide rods 6 a, 6 b, 6 c, 6 d,6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f and the base plate, not shown, ofthe manufacturing apparatus and a motor for rotating the ball screw.Such driving member is a known feed member, so that the details thereofare not shown herein.

The side edge pressing mechanism is provided, as shown in FIGS. 19, 20A,20B, 21A, 21B, 22A and 22B, with plate-shaped pressing members 235, 235for pressing the side edges 3 c, 3 c of the continuous member 3 of theseparator toward the front end direction of the guide rods 6 a, 6 b, 6c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f till the time ofwithdrawing the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7d, 7 e, 7 f from the valley grooves 3 a of the zigzag-shaped continuousmember 3 of the separator from the time of zigzag-folding the continuousmember 3 by intersecting the rows of the guide rods 6 a, 6 b, 6 c, 6 d,6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f with each other.

Each of the pressing members 235, 235 is disposed for each of the rowsof the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7f, and the pressing members 235, 235 are connected to the verticalframes 8, 9, respectively, through holding members 235 a, 235 a integralwith the pressing members 235, 235, respectively, so as to be movedintegrally with the respective rows of the guide rods 6 a, 6 b, 6 c, 6d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f at the time when the rows of theguide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 fintersect with each other.

Furthermore, the holding members 235 a, 235 a of the respective pressingmembers 235, 235 are connected, as shown in FIGS. 22A and 22B, to thevertical frames 8, 9 to be slidable in the axial direction of the guiderods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f, andsupported to the base plate of the manufacturing apparatus to beslidable between the solid line position and two-dot-chain line positionas shown in FIGS. 22 a and 22B.

Springs are disposed as elastic member, not shown, between therespective holding members 235 a, 235 a and the base plate, andaccording to the location of these springs, the pressing members 235,235 and the holding members 235 a, 235 a are always urged to the solidline position.

The respective pressing members 235, 235 have front end edges 235 b, 235b, as shown in FIGS. 22A and 22B, contacting the side edges 3 c, 3 c ofthe zigzag-folded continuous member 3 of the separator. According to theurging force of the springs, not shown, as shown in FIG. 21A, the frontend edges 235 b, 235 b of the pressing members 235, 235 slightly contactthe side edges 3 c, 3 c of the continuous member 3 at the solid lineposition. As shown in FIGS. 22A and 22C, when the guide rods 6 a, 6 b, 6c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f are withdrawn from therespective valley grooves 3 a of the separator, the holding members 235a, 235 a of the respective pressing members 235, 235 are pushed by thevertical frames 8 and 9 and retired to the two-dot-chin-line positionagainst the urging force of the springs, and the front end edges 235 b,235 b of the respective pressing members 235, 235 are separated from theside edges 3 c, 3 c of the continuous member 3 of the separator.

As mentioned above, from the time of zigzag-folding the continuousmember 3 of the separator by the intersection of the rows of the guiderods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f to thetime of withdrawing the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b,7 c, 7 d, 7 e, 7 f from the continuous member 3, the meandering motionof the continuous member 3 at the zigzag-folding time can be preventedbecause the continuous member 3 is pressed in the front end direction ofthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f,and the zigzag-shaped continuous member 3 can be supported so as not todamage the mount portions thereof at the time of withdrawing the guiderods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f.

Further, as shown in FIG. 19, notches 235 c are formed to the front endedges 235 b, 235 b of the pressing members 235, 235 so as not tointerfere with the front ends of the guide rods 6 a, 6 b, 6 c, 6 d, 6 eand 7 a, 7 b, 7 c, 7 d, 7 e, 7 f at the time of intersecting the rows ofthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f.However, such notches may be eliminated in a case where the front endportions of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7d, 7 e, 7 f may be made short so as not to cause interfering, or theguide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f arecontrolled so that the front end portions thereof are pulled in thevalley grooves 3 a of the continuous member 3 at the time ofzigzag-folding thereof.

The electrode insertion mechanism is provided with electrode conveyingtrays 13 a, 13 b, 13 c, 13 d, 13 e and 14 a, 14 b, 14 c, 14 d, 14 e foralternately inserting the positive electrodes 4 and the negativeelectrodes 5 in the respective valley grooves 3 a of the continuousmember 3 of the separator which is zigzag-folded by the guide rods 6 a,6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f of the zigzagfolding mechanism.

Further, as shown in FIGS. 19 and 20C, the electrode conveying trays 13a, 13 b, 13 c, 13 d, 13 e and 14 a, 14 b, 14 c, 14 d, 14 e are preparedby the same numbers as those of the positive and negative electrodes 4and 5 necessary for one electrode assembly 2 and arranged horizontallyat the rear side of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b,7 c, 7 d, 7 e, 7 f.

As shown in FIG. 20C, the electrode conveying trays 13 a, 13 b, 13 c, 13d, 13 e and 14 a, 14 b, 14 c, 14 d, 14 e are disposed correspondingly tothe guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f,and the respective rear end portions of the rows are connected to thesupport frames 28, 28, respectively.

The respective frames 228, 228 are connected to the piston rods 229 a,229 a of piston cylinder assemblies 229, 229 which are expanded andcontracted in the conveying direction of the positive and negativeelectrodes 4 and 5, and the respective piston cylinder assemblies 229,229 are placed on reciprocating tables 230, 230, which are reciprocallymovable in the conveying direction of the positive and negativeelectrodes 4 and 5.

The reciprocating table 230 is connected to a nut 232 screw-engaged witha ball screw 231 as a feed screw disposed to be rotatable on the baseplate, not shown, of the manufacturing apparatus. The ball screw 231 isrotated by a motor, not shown.

When the ball screws 231, 231 are rotated, the electrode conveying trays213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e, onwhich the positive and negative electrodes 4 and 5 are placed, are movedin unit of the respective rows as shown in FIG. 21C into the respectivevalley grooves 3 a of the separator continuous member 3 to be folded inthe zigzag form by the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b,7 c, 7 d, 7 e, 7 f.

Although it is possible to move the electrode conveying trays 213 a, 213b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e after the zigzagformation of the continuous member 3 of the separator by the guide rods,the electrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214b, 214 c, 214 d, 214 e may be preferably moved on the side of theseparator continuous member 3 at the same time of the zigzag-folding ofthe separator continuous member 3 by intersecting the respective rows ofthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f.According to such motion, it becomes possible to insert the positive andnegative electrodes 4 and 5 into the respective valley grooves 3 a ofthe continuous member 3 of the separator while folding the continuousmember 3 into zigzag form, thus shortening the takt time.

As shown in FIG. 24C, the electrode conveying trays 213 a, 213 b, 213 c,213 d, 213 e and 214 b, 214 c, 214 d, 214 e are thereafter removedrearward from the valley grooves 3 a of the separator by the contractivemotion of the piston cylinder assemblies 229, 229. On the time of theretiring motion of the electrode conveying trays 213 a, 213 b, 213 c,213 d, 213 e and 214 b, 214 c, 214 d, 214 e, the positive and negativeelectrodes 4 and 5 remain in the valley grooves 3 a of the separatorcontinuous member 3, so that, as shown in FIGS. 20A to 20C, the pressingmembers 211, 211 and 215, 215 are arranged so as to sandwich the rows ofthe electrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214b, 214 c, 214 d, 214 e, respectively, from both lateral sides thereof.

The pressing members 211, 211 and 215, 215 are formed as vertical rodsabutting against the rear edges of the positive and negative electrodes4 and 5 projecting over both the lateral sides of the electrodeconveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214d, 214 e, and arranged on both the lateral sides of the respective rowsthereof.

Since these pressing members 211, 211 and 215, 215 are arranged in therear side of the positive and negative electrodes 4 and 5 projectingover both sides of the electrode conveying trays 213 a, 213 b, 213 c,213 d, 213 e and 214 b, 214 c, 214 d, 214 e, so that when the electrodeconveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214d, 214 e are removed rearward from the valley grooves 3 a of theseparator, the positive and negative electrodes 4 and 5 remain in therespective valley grooves 3 a of the separator.

As shown in FIG. 19 and FIGS. 21A and 21B, stoppers 216 and 217 forpushing the positive and negative electrodes 4 and 5 inserted into therespective valley grooves 3 a of the separator continuous member 3 ofthin the longitudinal direction of the guide rods 6 a, 6 b, 6 c, 6 d, 6e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f are provided as occasion demands onboth sides along the longitudinal direction of the guide rods.

Each of the stoppers 216 and 217 is reciprocally movable by the pistoncylinder assembly, not shown, in the longitudinal direction of the guiderods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f. One ofthe stoppers 216 is inserted into the respective valley grooves 3 a ofthe separator by one of the rows of electrode conveying trays 213 a, 213b, 213 c, 213 d and 213 e and abut against the side edges of all thepositive electrodes 4 projecting over the side edge 3 c of thecontinuous member 3 of the separator, On the other hand, the other oneof the stoppers 217 is inserted into the respective valley grooves 3 aof the separator by the other one of the rows of electrode conveyingtrays 214 b, 214 c, 214 d and 214 e and abut against the side edges ofall the negative electrodes 5 projecting over the other side edge 3 c ofthe continuous member 3 of the separator.

According to the location of these stoppers 216 and 217, the positiveelectrodes 4 and the negative electrodes 5 inserted into the respectivevalley grooves 3 a of the separator are accurately positioned in thelongitudinal direction of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7a, 7 b, 7 c, 7 d, 7 e, 7 f.

The guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 fcan be withdrawn from the respective valley grooves 3 a of the separatoras shown in FIGS. 22A to 22C by the guide rod withdrawing mechanism.This guide rod withdrawing mechanism includes, for example, a pistoncylinder assembly, not shown. Such piston cylinder assembly isinterposed between the vertical frames 208 and 209 of the guide rods 6a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f and the baseplate, not shown, and in accordance with the operation (contraction orexpansion) of the piston cylinder assembly, the guide rods 6 a, 6 b, 6c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f are removed outside therespective valley grooves 3 a of the continuous member 3 of theseparator, as shown in FIGS. 22A to 22C, or returned to the originalposition as shown in FIGS. 19 and 20A to 20C.

The piston cylinder assembly of this guide rod withdrawing mechanismserves to intersect the rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 eand 7 a, 7 b, 7 c, 7 d, 7 e, 7 f, to hold the respective driving membersfor folding the continuous member 3 of the separator together with therespective vertical frames 208 and 209 and to expand or contract thesame.

The electrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214b, 214 c, 214 d, 214 e are connected to the base plate, not shown,through the ball screw 231 as mentioned above. After the withdrawal ofthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 fby the guide rod withdrawing mechanism from the valley grooves 3 a ofthe continuous member 3 of the separator folded into the zigzag shape,when the ball screw 231 is further rotated, the electrode conveyingtrays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 efurther advance as shown in FIGS. 23A and 23C so as to push the positiveelectrodes 4 and the negative electrodes 5 into the respective valleygrooves 3 a of the separator.

According to the further advancing of the electrode conveying trays 213a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e, as shownin FIG. 23C, the folded lines 234 are formed to the bottom portions ofthe respective valley grooves 3 a of the separator by the folding lineforming mechanism.

As shown in FIG. 19 and FIG. 23C, the folding line forming mechanism isprovided with receiving portions 237 for forming the folded lines 234 tothe bottom portions of the valley grooves 3 a by clamping the protrudedportions 236 formed to the front ends of the electrode conveying trays213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e and theprotruded portions 236 of the continuous member 3 of the separator.

The protruded portions 236 are formed to the front ends, in form ofblade, of the electrode conveying trays 213 a, 213 b, 213 c, 213 d, 213e and 214 b, 214 c, 214 d, 214 e. The protruded portions 236 may beformed by making thin the electrode conveying trays 213 a, 213 b, 213 c,213 d, 213 e and 214 b, 214 c, 214 d, 214 e or sharpening the front endsthereof, respectively, or may be formed by attaching independentlyformed blade members to the front ends of the electrode conveying trays213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e.

Furthermore, the front ends or protruded portions 236 of the electrodeconveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214d, 214 e may be sharpened at portions contacting to the continuousmember 3 of the separator, or may be formed with curved surfaces atportions abutting against the separator continuous member 3.

The receiving portions 237 are attached to the pressing members 211, 211and 215, 215 so as to oppose to each other with the protruded portions236 of the front ends of the electrode conveying trays 213 a, 213 b, 213c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e and the continuous member3 of the separator being interposed therebetween. Further, as shown inFIG. 19 and FIG. 23C, the receiving portions 237 are stretched as beamsbetween the opposed pair of the pressing members 211, 211 and 215, 215,and elastic pieces 237 a, such as rubber, having cushioning performancemay be disposed at portions against which the protruded portions 236abut.

As shown in FIGS. 23A to 23C, when the electrode conveying trays 213 a,213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e furtheradvance, and the positive and negative electrodes 4 and 5 are pushedfurther inside the valley grooves 3 a of the separator, the continuousmember 3 of the separator are sandwiched by the protruded portions 236of the front ends of the electrode conveying trays 213 a, 213 b, 213 c,213 d, 213 e and 214 b, 214 c, 214 d, 214 e and the receiving portions237, and the folded lines 234 are formed to the bottom portions of therespective valley grooves 3 a of the continuous member 3 of theseparator.

Further, it may be possible that the receiving portions 237 are notmounted to the pressing members 211, 211 and 215, 215 so as to operateindependently of the pressing members 211, 211 and 215, 215. Thereceiving portions 237 may advance to the positions receiving theprotruded portions 236 only at the time of forming the folded lines 234.

As shown in FIG. 20C and FIGS. 25A to 25C, the pressing mechanismincludes a pusher 218 vertically movable on the surface table 212. Thepusher 218 pushes the continuous member 3 of the separator formed withthe folded lines 234 in the zigzag direction so as to provide the flatshape. According to this operation, the continuous member 3 of theseparator is made flat so as to provide the thickness to the extent ofthat of the electrode assembly 2 shown in FIG. 2 in a state ofsandwiching the positive and negative electrodes 4 and 5.

The electrode assembly 2 will be manufactured by the manufacturingapparatus of the structure mentioned above according to the procedureswhich will be mentioned hereunder.

(1) As shown in FIG. 19 and FIGS. 20A to 20C, the continuous member ofthe separator is inserted between one and the other one rows of theguide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 farranged in the zigzag form. The front end of the continuous member 3 isclamped by the clamp 12 a. The continuous member 3 is reeled out fromthe roll on which the continuous member 3 was wound up, and tensionedperpendicularly with small tension between the guide rods 6 a, 6 b, 6 c,6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f.

(2) In FIGS. 20A and 20C, the rows of the guide rods 6 a, 6 b, 6 e, 6 d,6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f are moved horizontally in thearrowed direction, and as shown in FIGS. 21A to 21C, the guide rods 6 a,6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f are crossed betweenthe rows thereof. Accordingly, the continuous member 3 of the separatoris folded into zigzag form, and necessary numbers of the valley grooves3 a for one electrode assembly 2 are simultaneously formed to theseparator continuous member 3, thus remarkably reducing the takt timerequired for the manufacture of the electrode assembly 2.

In addition, since the separator is folded in the zigzag form byintersecting the respective rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f, the deep valley grooves 3 a can beformed which enables the large-sized positive and negative electrodes 4and 5 to be inserted into the valley grooves 3 a, and it is madepossible to manufacture the electrode assembly 2 having large capacity.

Since the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7e, 7 f are formed as rotatable rollers, the tension applied to thecontinuous member 3 of the separator is loosened, and the continuousmember is smoothly folded into the zigzag form.

Further, when the rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7a, 7 b, 7 c, 7 d, 7 e, 7 f are intersected, air is jetted from thenozzles 10 formed to the surface of the guide rods 6 a, 6 b, 6 c, 6 d, 6e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f toward the continuous member 3 of theseparator. According to this operation, the friction between thecontinuous member 3 and the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a,7 b, 7 c, 7 d, 7 e, 7 f at the time of the zigzag-folding of thecontinuous member 3 can be reduced, and the tension applied to thecontinuous member 3 can be loosened. As a result, the time required forthe zigzag-folding of the continuous member 3 can be reduced and thebreakage thereof can be prevented.

(3) At the same time when the rows of the guide rods 6 a, 6 b, 6 c, 6 d,6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f are moved in the horizontaldirection as shown with arrows in FIGS. 20A to 20C, the ball screw 231is rotated by one turn, and every lateral groups of the electrodeconveying trays 213 a, 213 b, 213 c, 213 d, 213 e, 214 b, 214 c, 214 d,214 e and the pressing members 211, 211 and 215, 215 are movedintegrally in the arrowed directions.

At this time, the positive electrodes 4 are preliminarily placed on oneof the rows of the electrode conveying trays 213 a, 213 b, 213 c, 213 dand 213 e and on the other hand, the negative electrodes 5 arepreliminarily placed on the other one of the rows of the electrodeconveying trays 214 b, 214 c, 214 d and 214 e. Accordingly, as shown inFIGS. 21A to 21C, the positive and negative electrodes 4 and 5 arealternately inserted into the respective valley grooves 3 a of thecontinuous member 3 of the separator while being folded into the zigzagform.

As mentioned above, the zigzag-folding of the continuous member 3 of theseparator and the insertion of the positive and negative electrodes 4and 5 can be simultaneously performed by zigzag-folding the continuousmember 3 of the separator and alternately inserting the positive andnegative electrodes 4 and 5 into the respective valley grooves 3 a byintersecting the respective rows of the guide rods 6 a, 6 b, 6 c, 6 d, 6e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f, thus further shortening the takttime.

(4) Furthermore, as shown in FIGS. 20A, 20B and FIG. 21A, when thecontinuous member 3 of the separator is zigzag-folded, the front endedges 235 b, 235 b of the pressing members 235, 235 of the side edgepressing mechanism advance so as to be in contact with both the sideedges 3 c, 3 c of the separator continuous member 3 by the urging forceof a spring, not shown. According to this motion, the meanderingmovement of the continuous member 3 at the zigzag-folding time can beprevented from causing and the continuous member 3 can be accuratelyfolded into the zigzag form.

(5) When the movement of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a,7 b, 7 c, 7 d, 7 e, 7 f in the intersecting direction is stopped and therespective front ends of the electrode conveying trays approach theguide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f, therotations of the ball screws 231, 231 are stopped, and whole theelectrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b,214 c, 214 d, 214 e stop together with the reciprocal tables 230, 230.

(6) As shown in FIGS. 21A to 21C, the pressing members 211, 211 and 215,215 also advance toward the continuous member side and then stoptogether with the electrode conveying trays 213 a, 213 b, 213 c, 213 d,213 e and 214 b, 214 c, 214 d, 214 e in the state of contacting with therear edges of the positive and negative electrodes 4 and 5 placed in theelectrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b,214 c, 214 d, 214 e.

(7) As shown in FIGS. 21A to 21C, when the electrode conveying trays 213a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e on whichthe positive and negative electrodes 4 and 5 are placed are moved intothe valley grooves 3 a of the continuous member 3 of the separator, therespective stoppers 216 and 217 advance in the longitudinal direction ofthe guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f.Then, one of the stoppers 216 is inserted into the respective valleygrooves 3 a of the continuous member 3 by the one of the rows of theelectrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and abutagainst the side edges of all the positive electrodes 4 projecting fromthe side edge 3 c of the continuous member 3. Furthermore, the other oneof the stoppers 217 is inserted into the respective valley grooves 3 aof the continuous member 3 by the other one of the rows of the electrodeconveying trays 214 b, 214 c, 214 d, 214 e and abut against the sideedges of all the negative electrodes 5 projecting from the other side(opposite side) of the continuous member 3. According to this operation,the positive electrodes 4 and the negative electrodes 5 inserted intothe respective valley grooves 3 a of the separator continuous member 3can be accurately positioned in the longitudinal direction of the guiderods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f.

(8) Then, the piston cylinder assemblies, not shown, are operated tomove the vertical frames 8 and 9 in the direction separating from thecontinuous member 3 of the separator, as shown in FIGS. 22A and 22B.

According to this motion, the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7a, 7 b, 7 c, 7 d, 7 e, 7 f are moved in the longitudinal directionthereof and removed outside the valley grooves 3 a of the continuousmember 3. As a result, the valley grooves 3 a of the continuous member 3become empty.

When the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e,7 f are withdrawn from the zigzag-shaped continuous member 3, the sideedges 3 c, 3 c of the zigzag-shaped continuous member 3 are pressed inthe front end direction of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7a, 7 b, 7 c, 7 d, 7 e, 7 f by the pressing members 235, 235, so that thecontinuous member 3 of the separator can be finely protected so as notto destroy the zigzag folded mount portions thereof.

(9) The piston cylinder assemblies for reciprocally moving the guiderods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f serve tomove the respective vertical frames 208 and 209 against the urging forceof the spring, not shown, to further rearward direction from theposition at which the vertical frames 208 and 209 abut against the rearends of the holding portions 235 a, 235 a of the pressing members 235,235. According to this motion, the front end edges of the respectivepressing members 235, 235 move from the position shown with solid linesin FIGS. 22A and 22 b to the position shown with two-dot-chain lines andseparate from the respective side edges 3 c, 3 c of the separatorcontinuous member 3.

(10) As shown in FIG. 23C, when the ball screws 231, 231 are furtherrotated in one direction, the electrode conveying trays 213 a, 213 b,213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e placed on thereciprocal tables 230, 230 further advance together with the pressingmembers 211, 211 and 215, 215.

Accordingly, as shown in FIG. 23C, the continuous member 3 of theseparator is sandwiched between the protruded portions of the electrodeconveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214d, 214 e and the receiving portions 237, thus forming the folded linesto the bottom portions of the respective valley grooves 3 a of theseparator continuous member 3.

Further, as shown in FIGS. 23A to 23C, the pressing members 211, 211 and215, 215 push the positive and negative electrodes 4 and 5 furtherdeeply inside the respective valley grooves 3 a of the separator in astate of contacting to the rear edges of the positive and negativeelectrodes 4 and 5 placed on the electrode conveying trays 213 a, 213 b,213 c, 213 d, 213 e, 213 f, 213 g, 213 h, 213 i and 213 j. According tothis operation, areas opposing to the positive and negative electrodes 4and 5 through the continuous member 3 of the separator increase, whichresults in the increasing of the electric capacity and improvement ofthe battery performance. In addition, the separator can be moreeffectively utilized.

(11) As shown in FIG. 24C, according to the contraction motion of thepiston cylinder assemblies 229, 229, the electrode conveying trays 213a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e are removedat once from the valley grooves 3 a of the continuous member 3 of theseparator.

At this time, as shown in FIGS. 24A to 24C, the pressing members 211,211 and 215, 215 stop at the advancing position and maintain the stateabutting against the rear edges of the positive and negative electrodes4 and 5. Therefore, at the retiring time of electrode conveying trays213 a, 213 b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e, thepositive and negative electrodes 4 and 5 are pushed inside the valleygrooves 3 a of the continuous member 3 of the separator from theposition on the electrode conveying trays 213 a, 213 b, 213 c, 213 d,213 e and 214 b, 214 c, 214 d, 214 e, and they are then retired in anempty state with the positive and negative electrodes 4 and 5 remainingin the valley grooves 3 a of the separator.

(12) As shown in FIGS. 25A to 25C, the pusher 218 strongly pushes thecontinuous member 3 of the separator toward the surface plate 212 in thezigzag direction.

As mentioned above, since the folded lines 34 are formed to therespective valley grooves 3 a of the continuous member 3 of theseparator, the continuous member 3 can be accurately folded into flatshape without loosening its shape, and a flat laminated member, in whichthe folded continuous member 3 and the positive and negative electrodes4 and 5 are alternately laminated, can be formed.

(13) The front end of the continuous member 3 folded into the zigzagform is released from the clamp 212 a, and the rear end thereof is cutoff from the continuous member on the roll 3 b side by a cutter 233shown in FIG. 20C, and then, the electrode assembly 2 shown in FIG. 2can be completed. This electrode assembly 2 is accommodated in thebattery case 1 to thereby constitute a cell.

Eighth Embodiment

As shown in FIG. 26, an apparatus for manufacturing the electrodeassembly 22 shown in FIG. 9 has a structure provided with a plurality ofguide rods 6 a, 6 b, 6 c and 7 a, 7 b, 7 c and 7 d arranged in thezigzag form and other structures. However, between one and the otherrows of these guide rods, the continuous laminated member 23 isinserted. Further, all the electrode conveying trays 13 a, 13 b, 13 cand 14 b, 14 c can convey only the positive electrodes 4 into the valleygrooves 23 a of the laminated member 23. Except for these structures,the electrode assembly 22 can be manufactured by the apparatus of thestructure similar to that of the seventh embodiment with similarprocedures.

In this eighth embodiment, it is allowed for the apparatus to have thevalley grooves 23 a of the laminated member 3 into which only thepositive electrodes 4 are inserted, so that by manufacturing theelectrode assembly 22 having the performance similar to that of theelectrode assembly 2 of the seventh embodiment, the number of thezigzag-folding of the laminated member 23 can be reduced half in numberin comparison with the case of the seventh embodiment, and accordingly,the numbers of the guide rods 6 a, 6 b, 6 c and 7 a, 7 b, 7 c, 7 d andthe electrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214b, 214 c, 214 d, 214 e can be also reduced half resulting in the furthershortening of the takt time.

In this eighth embodiment, the pressing members 235, 235 are provided asside edge pressing mechanism as like as in the seventh embodiment, andthe front end edges 235 b, 235 b thereof contact to one side edge 23 bof the laminated member 23 and side edge 24 b of the side edge 24 b ofthe continuous member 24.

Furthermore, as the folded line forming mechanism similar to that in theseventh embodiment, the protruded portions 236 are provided for thefront ends of the electrode conveying trays 13 a, 13 b, 13 c and 14 b,14 c, 14 d, 14 e, and the receiving portions 237 opposing to theprotruded portions 236 are mounted to the pressing members 211, 211 and215, 215.

Further, the same reference numerals are added to members or portionscorresponding to those in the seventh embodiment and the duplicatedexplanations are hence omitted herein.

Ninth Embodiment

In this ninth embodiment, the pitch changing mechanism for narrowing thedistance in the respective rows in the perpendicular direction of theelectrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 e and 214 b,214 c, 214 d, 214 e is provided to the respective support frames 228,228 of the electrode conveying trays 213 a, 213 b, 213 c, 213 d, 213 eand 214 b, 214 c, 214 d, 214 e in the apparatus for manufacturing theelectrode assembly for the rectangular battery shown in the seventhembodiment.

This pitch changing mechanism is composed, as typical example, of a linkmechanism 225 shown in FIG. 27.

The link mechanism 227 is a parallel motion mechanism including aplurality of links 225 a, 225 a, having the same length, which arepivoted in X-shape and coupled with pins in the perpendicular direction.Shafts 226 horizontally holding the electrode conveying trays 213 a, 213b, 213 c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e pass through thepivot points, respectively, of the respective paired links 225 a, 225 awhich are coupled in X-shape, and one end of each shaft 226 is insertedinto a guide groove 228 a of a guide member 228 extending in theperpendicular direction. In order to easily hold the electrode conveyingtrays 213 a, 213 b, 213 c, 213 d, 213 e horizontally, a plurality ofrows of such link mechanisms may be arranged as occasion demands.

Although not shown, similar link mechanisms and guide members may beprovided for the electrode conveying trays 214 b, 214 c, 214 d, 214 e ofthe other row.

According to the structure mentioned above, as shown in FIG. 22C, afterthe withdrawal of the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7c, 7 d, 7 e, 7 f from the valley grooves 3 a of the continuous member 3of the separator, when the link mechanisms are contracted in theperpendicular direction, the electrode conveying trays 213 a, 213 b, 213c, 213 d, 213 e and 214 b, 214 c, 214 d, 214 e are lowered in theperpendicular direction with constant distances being maintained in therespective rows thereof and the distances are narrowed in theperpendicular direction. As a result, the distance of the continuousmember 3 in the zigzag direction is narrowed, and as shown in FIG. 23C,in the process forming the folded lines 234 in the valley grooves 3 a ofthe continuous member 3 of the separator, the folded lines 234 can beeasily formed to the separator continuous member 3, and in addition, inthe pressing process shown in FIG. 25C, the continuous member 3 of theseparator can be accurately folded in the perpendicular direction.

Tenth Embodiment

In this tenth embodiment, the side edge pressing mechanism in themanufacturing apparatus of the electrode assembly for the rectangularbattery shown in the seventh embodiment is constructed so as to guideboth the side edges 3 c, 3 c of the continuous member 3 of the separatorby the ring-shaped pressing member 238 as shown in FIGS. 28A to 28C.

That is, the ring-shaped pressing member 238 is provided to be rotatableand slidable over all or a part of the guide rods 6 a, 6 b, 6 c, 6 d, 6e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f, and are held to be rotatable tobrackets 239 a formed to the front ends of the respective holdingmembers 239, 239. The respective holding members 239, 239 are connectedto the vertical frames 8 and 9, as like as in the seventh embodiment,and coupled to the base plate, not shown, of the manufacturing apparatusthrough a spring, not shown.

Then, the function of such side edge pressing mechanism of the structurementioned above will be explained hereunder.

As shown in FIG. 28A, when the continuous member 3 of the separator isinserted between one and the other one rows of the guide rods 6 a, 6 b,6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f arranged in the zigzagform, the holding members 239, 239 advance toward the side edges 3 c, 3c of the separator continuous member 3 by the actuation of the pistoncylinder assembly, not shown, and the end surfaces of the pressingmembers 238 as the rings contact to both the side edges 3 c, 3 c of thecontinuous member 3, respectively.

Then, as shown in FIG. 28B, the rows of the guide rods 6 a, 6 b, 6 c, 6d, 6 e and 7 a, 7 b, 7 c, 7 d, 7 e, 7 f are intersected with each other,the continuous member 3 of the separator is folded into the zigzagshape, and the valley grooves 3 a of the number necessary for the oneelectrode assembly 2 are simultaneously formed to the continuous member3 of the separator.

When the continuous member 3 is folded into the zigzag shape, both theside edges 3 c, 3 c of the continuous member 3 are guided by thepressing member 238, so that the meandering motion of the continuousmember 3 is prevented and the continuous member 3 can be exactly foldedinto zigzag form in the perpendicular direction.

Thereafter, by the actuation of the piston cylinder assembly, not shown,as shown in FIG. 28C, the vertical frames 8 and 9 are moved in thedirection apart from the continuous member 3 of the separator, and atthe same time, the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c,7 d, 7 e, 7 f are moved in their longitudinal directions to therebyseparate outside from the valley grooves 3 a of the separator.

At the time when the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7c, 7 d, 7 e, 7 f are withdrawn from the continuous member 3 in thezigzag arrangement, the side edges 3 c, 3 c of the separator continuousmember 3 are pressed toward the front end directions of the guide rods 6a, 6 b, 6 c, 6 d, 6 e and 6 a, 7 b, 7 c, 7 d, 7 e, 7 f by the pressingmember 238, so that the mount portions of the zigzag-shaped continuousmember 3 are not deformed and finely maintained.

After the guide rods 6 a, 6 b, 6 c, 6 d, 6 e and 7 a, 7 b, 7 c, 7 d, 7e, 7 f are removed outside the valley grooves 3 a of the separator, whenthe vertical frames 8 and 9 are further moved, the respective verticalframes 8 and 9 abut against the holding members 239, 239, respectively,as shown with solid lines in FIG. 28C, and against the urging force ofthe spring, not shown, the respective pressing members 238 are movedtogether with the pressing members 239, 239 to the position shown withtwo-dot-chain lines. As a result, the end surfaces of both the pressingmembers 238 are separated from the side edges 3 c, 3 c of the continuousmember 3.

Thereafter, as like as the seventh embodiment, the same procedures asthose represented by FIGS. 23A to 23C and FIGS. 25A to 25C are performedto thereby manufacture the electrode assembly 2.

Further, like reference numerals are added to members or portions shownin FIGS. 28A to 28C corresponding to those in the seventh embodiment,and duplicated explanations are omitted herein.

It is further noted that the present invention is not limited to fromthe first to the tenth embodiments described above, and many otherchanges and modifications may be made without departing from the scopeof the appended claims.

For example, in the above first to tenth embodiment, although thepresent invention was explained with reference to the lithium ionsecondary battery, the present invention is applicable to a batteryother than the lithium ion battery or a primary battery. In addition, inthe above first to tenth embodiment, although both the rows of the guiderods are moved at the time of intersecting the rows of the guide rods,the zigzag-folding may be preformed by moving only one row of the guiderods without moving the other row of guide rods. According to suchstructure, the driving unit for moving the row of the guide rods can bemade simple and hence the cost-down can be achieved. Moreover, thenumbers of the guide rods and the electrode conveying trays may bechanged to be increased or decreased without being limited to the firstand tenth embodiments.

What is claimed is:
 1. A method of manufacturing a rectangular battery, comprising the steps of: arranging a plurality of guide members in zigzag form in a perpendicular direction; inserting a continuous member of a separator having a first surface and an opposite facing second surface between rows of the guide members; folding, into a zigzag form, the continuous member by intersecting the rows of the guide members in a horizontal direction; inserting, alternately, positive electrodes and negative electrodes in respective valley grooves of the zigzag-folded continuous member such that the positive electrodes are inserted into first valley grooves formed in a first surface side of the separator in a state in which the guide members are preliminarily placed in the grooves on the first surface side, and such that the negative electrodes are inserted into second valley grooves formed in a second surface side of the separator in a state in which the guide members are preliminarily placed in the grooves on the second surface side; withdrawing the guide members from the respective valley grooves of the continuous member; and pressing, thereafter, the continuous member in the zigzag direction so as to make flat the continuous member.
 2. The method of manufacturing a rectangular battery according to claim 1, wherein the positive electrodes and the negative electrodes are alternately inserted into the respective valley grooves of the continuous member while folding the continuous member by intersecting the respective rows of the guide members.
 3. The method of manufacturing a rectangular battery according to claim 1, wherein a distance between the rows of the guide members is narrowed after insertion of both the positive and negative electrodes into the valley grooves of the continuous member in the zigzag form.
 4. The method of manufacturing a rectangular battery according to claim 1, wherein both the positive and negative electrodes inserted into the valley grooves of the continuous member are pressed in an extending direction of the valley grooves.
 5. The method of manufacturing a rectangular battery according to claim 1, wherein when the guide members are withdrawn from the respective valley grooves of the continuous member, the continuous member is pressed in the zigzag direction.
 6. The method of manufacturing a rectangular battery according to claim 1, wherein after the guide members are withdrawn from the respective valley grooves of the continuous member, the positive and negative electrodes are further pushed into the respective valley grooves before the pressing of the continuous member into a flat shape.
 7. The method of manufacturing a rectangular battery according to claim 1, wherein the guide members are constructed as guide rods.
 8. The method of manufacturing a rectangular battery according to claim 7, wherein the guide rods are rotatable guide rollers.
 9. The method of manufacturing a rectangular battery according to claim 7, wherein the guide rods are semicircular cylindrical members.
 10. The method of manufacturing a rectangular battery according to claim 1, wherein when the rows of the guide members are intersected with each other, air is ejected from surfaces of the guide members toward the continuous member.
 11. The method of manufacturing a rectangular battery according to claim 1, wherein friction reducing material layers are formed to surfaces of the guide members contacting to the continuous member.
 12. The method of manufacturing a rectangular battery according to claim 1, wherein the guide members are guide plates.
 13. The method of manufacturing a rectangular battery according to claim 12, wherein the guide plates are formed to inclining plates inclining toward intersecting side front ends thereof.
 14. The method of manufacturing a rectangular battery according to claim 12, wherein rotatable rollers are mounted to intersecting side front ends of the guide plates.
 15. The method of manufacturing a rectangular battery according to claim 14, wherein when the rows of the guide plates are intersected with each other, air is ejected from surfaces of the rollers toward the continuous member.
 16. The method of manufacturing a rectangular battery according to claim 14, wherein a friction reducing material layer is formed on a surface of at least one of the roller or guide plate contacting to the continuous member.
 17. The method of manufacturing a rectangular battery according to claim 1, wherein the guide members are withdrawn from the respective valley grooves of the continuous member, folded lines are formed to bottom portions of the respective valley grooves of the continuous member, and thereafter, the continuous member is pressed in the zigzag direction so as to make flat the continuous member.
 18. The method of manufacturing a rectangular battery according to claim 17, wherein the side edges of the continuous member are pressed in the front end direction of the guide members from the time of zigzag-folding the continuous member till the time of withdrawing the guide members.
 19. The method of manufacturing a rectangular battery according to claim 17, wherein a distance of the continuous member in the zigzag direction is narrowed after the withdrawal of the guide members from the respective valley grooves of the zigzag-shaped continuous member.
 20. An apparatus for manufacturing an electrode assembly for a rectangular battery in which positive electrodes and negative electrodes are alternately laminated with a separator being interposed therebetween, the apparatus comprising: a zigzag folding mechanism provided with a plurality of guide members arranged in zigzag form in a perpendicular direction, and configured to fold a continuous member of the separator into a zigzag-folded form by intersecting rows of the guide members in a horizontal direction when the continuous member is inserted between first and second rows of the guide members; an electrode inserting mechanism for alternately inserting the positive electrodes and the negative electrodes in the respective valley grooves of the zigzag-folded continuous member, such that the positive electrodes are inserted into first valley grooves formed in a first surface side of the separator in a state in which the guide members are preliminarily placed in the grooves on the first surface side, and such that the negative electrodes are inserted into second valley grooves formed in a second surface side of the separator in a state in which the guide members are preliminarily placed in the grooves on the second surface side; a guide member withdrawing mechanism for withdrawing the guide members from the respective valley grooves of the continuous member; and a press mechanism for pressing the continuous member in the zigzag direction so as to flatten the continuous member.
 21. A method of manufacturing a rectangular battery, comprising the steps of: arranging two vertical rows of guide members, each of the vertical rows being spaced from each other by a horizontal distance, the guide members of a first of the vertical rows arranged to be staggered with respect to the guide members of a second of the vertical rows such that the guide members of both of the first and second vertical rows form a zigzag pattern; inserting a continuous member, having a first surface on a first side of the continuous member and an opposite facing second surface on a second side of the continuous member, into a space between the first vertical row and the second vertical row; moving one of the first and second vertical rows in a direction toward an other of the first and second vertical rows such that the first and second vertical rows respectively come into contact with the first and second surfaces of the continuous member, and continuing to move the one of the first and second vertical rows in the direction so that the guide members of the one of the first and second vertical rows pass through gaps between the guide members of the other of the first and second vertical rows, the guide members forcing portions of the continuous member through the gaps, thereby causing the continuous member to fold over itself and assume a zigzag-folded form comprising a plurality of alternating horizontal valley grooves; prior to withdrawal of the two vertical rows of guide members from the valley grooves of the folded continuous member, inserting positive electrodes into corresponding first valley grooves formed in the first side of the folded continuous member, and negative electrodes into corresponding second valley grooves formed in the second side of the folded continuous member; withdrawing the guide members from the valley grooves of the folded continuous member; and subsequent the withdrawing of the guide members, pressing the folded continuous member in a vertical direction so as to compress the valley grooves of the folded continuous member. 